Process for making an absorbent article comprising a topsheet/acquisition layer laminate

ABSTRACT

A process of making an absorbent article comprising the steps of providing a liquid permeable topsheet web extending substantially continuously in a machine direction, the topsheet web having a first and second surface, a liquid impermeable backsheet web extending substantially continuously in the machine direction and an acquisition layer having a first and second surface. The topsheet web and the acquisition layer comprise fibers. The process comprises the step of aligning the topsheet web and the acquisition layer in a face to face relationship such that the second surface of the topsheet web in in contact with the first surface of the acquisition layer. The process comprises the step of simultaneously mechanically deforming and combining the topsheet web together with the acquisition layer to provide a topsheet/acquisition layer laminate web having three-dimensional protrusions.

RELATED APPLICATIONS

This application claims priority under 35 U.S.C. §119(e) to U.S.Provisional Patent Application Ser. Nos. 62/049,516 (P&G 13530P),62/049,521 (P&G 13531PQ), 62/049,408 (P&G CM4137FPQ), 62/049,406 (P&GCM4136FPQ), 62/049,404 (P&G CM4135FPQ), 62/049,403 (P&G CM4134FPQ),62/049,401 (P&G CM4133FPQ), 62/049,397 (P&G CM4132FPQ), and 62/049,392(P&G CM4131FPQ), all of which were filed on Sep. 12, 2014, and to U.S.Provisional Patent Application Ser. Nos. 62/210,005 (P&G 13971PQ),62/210,014 (P&G 13972PQ), 62/210,020 (P&G 13973PQ), and 62/210,057 (P&GCM 4131P2Q), all of which were filed on Aug. 26, 2015. The entiredisclosures of all of the above-referenced U.S. Provisional PatentApplications are fully incorporated herein by reference.

FIELD OF THE INVENTION

A process of making an absorbent article comprising atopsheet/acquisition layer laminate is provided. Specifically, a processof making an absorbent article comprising a topsheet/acquisition layerlaminate, a dry-laid fibrous structure and an optional carrier layer isprovided.

BACKGROUND OF THE INVENTION

An absorbent article typically comprises a topsheet, a backsheet, and anabsorbent core disposed between the topsheet and the backsheet. Theabsorbent article includes an acquisition layer and optionally adistribution layer. The acquisition layer is able to receive the liquidbodily exudates from the topsheet in order to temporary store them.Then, the distribution layer can receive the liquid bodily exudates fromthe acquisition layer and distribute and transfer them to the absorbentcore in order to make efficient the use of the absorbent core. Suchabsorbent articles exhibit satisfactory fluid handling properties.

Three-dimensional topsheets have been developed; see for example U.S.Patent application US 2014/0121625 A1.

There still remains a need to further improve three-dimensionaltopsheets.

There is a need to develop a method to prepare a skin facing layerhaving a three-dimensional structure for an absorbent article providingimproved dryness perception and improved fluid handling properties e.g.less rewet on the skin facing layer, while the physical and perceptionalcomfort of the wearer as well as the leakage prevention are still met.

There is also a need to produce a skin facing layer having athree-dimensional structure in order to reduce the contact of the liquidbodily exudates with the skin of the wearer. It is desirable as wellthat the skin facing layer provides a softness/cushiness feeling for thecaregiver and the wearer.

SUMMARY OF THE INVENTION

A process of making an absorbent article is provided and comprises thesteps of:

-   -   (a) providing a liquid permeable topsheet web extending        substantially continuously in a machine direction, the topsheet        web having a first and second surface, a liquid impermeable        backsheet web extending substantially continuously in the        machine direction and an acquisition layer having a first and        second surface, the topsheet web and the acquisition layer        comprising fibers;    -   (b) aligning the topsheet web and the acquisition layer in a        face to face relationship such that the second surface of the        topsheet web is in contact with the first surface of the        acquisition layer;    -   (c) simultaneously mechanically deforming and combining the        topsheet web together with the acquisition layer to provide a        topsheet/acquisition layer laminate web having three-dimensional        protrusions,    -   wherein the three-dimensional protrusions are formed from the        fibers of the topsheet web and the acquisition layer, wherein a        majority of the three-dimensional protrusions each comprises a        base forming an opening, an opposed distal portion, and one or        more side walls between the bases and the distal portions of the        majority of the three-dimensional protrusions, wherein the base,        distal portion and the one or more side walls are formed by        fibers such that the majority of the three-dimensional        protrusions has only an opening at the base;    -   wherein a width of the acquisition layer is less than a width of        the topsheet web in a cross direction;    -   the topsheet/acquisition layer laminate web having a first        surface comprising the second surface of the acquisition layer;        and    -   (e) joining a portion of the backsheet web to a portion of the        topsheet web of the topsheet/acquisition layer laminate web such        that the first surface of the topsheet/acquisition layer        laminate web is facing towards the backsheet web.

The process may comprise the step of cutting into individual absorbentarticles comprising a backsheet, a topsheet and an acquisition layer,characterized in that the topsheet and acquisition layer are joined toform a topsheet/acquisition layer laminate.

The process may comprise the steps of:

-   -   (a) providing a dry-laid fibrous structure or a wet-laid fibrous        structure;    -   (b) depositing the dry-laid fibrous structure or the wet-laid        fibrous structure on the first surface of the        topsheet/acquisition layer laminate web or on the backsheet web;        and    -   (c) joining a portion of the backsheet web to a portion of the        topsheet web of the topsheet/acquisition layer laminate web        wherein the dry-laid fibrous structure or the wet-laid fibrous        structure is between the topsheet/acquisition layer laminate web        and the backsheet web.

A process of making an absorbent article is provided and comprises thesteps of:

-   -   (a) providing a liquid permeable topsheet web extending        substantially continuously in a machine direction, the topsheet        web having a first and second surface, a liquid impermeable        backsheet web extending substantially continuously in the        machine direction, an acquisition layer having a first and        second surface, a dry-laid fibrous structure and a carrier layer        web having a first and second surface, the topsheet web and the        acquisition layer comprising fibers;    -   (b) aligning the topsheet web and the acquisition layer in a        face to face relationship such that the second surface of the        topsheet web is in contact with the first surface of the        acquisition layer;    -   (c) simultaneously mechanically deforming and combining the        topsheet web together with the acquisition layer to provide a        topsheet/acquisition layer laminate web having three-dimensional        protrusions,    -   wherein the three-dimensional protrusions are formed from the        fibers of the topsheet web and the acquisition layer, wherein a        majority of the three-dimensional protrusions each comprises a        base forming an opening, an opposed distal portion, and one or        more side walls between the base and the distal portion of the        majority of the three-dimensional protrusions, wherein the base,        distal portion and the one or more side walls are formed by        fibers such that the majority of the three-dimensional        protrusion has only an opening at the base;    -   wherein a width of the acquisition layer is less than a width of        the topsheet web in a cross direction;    -   the topsheet/acquisition layer laminate web having a first        surface comprising the second surface of the acquisition layer;    -   (d) depositing the dry-laid fibrous structure on the first        surface of the carrier layer web; and    -   (e) joining a portion of the backsheet web to a portion of the        topsheet web of the topsheet/acquisition layer laminate web such        that the second surface of the carrier layer web is facing the        topsheet/acquisition layer laminate web or the backsheet web.

The process may comprise the step of cutting into individual absorbentarticles comprising a backsheet, a carrier layer, a topsheet and anacquisition layer characterized in that the topsheet and acquisitionlayer are joined to form a topsheet/acquisition layer laminate.

A majority of the three-dimensional protrusions may be more than 50% ormore than 60% or more than 70% or more than 80% or more than 90% or morethan 95% or more than 98% of the three-dimensional protrusions in thetopsheet/acquisition layer laminate web or in the topsheet/acquisitionlayer laminate.

The topsheet web and the acquisition layer in the topsheet/acquisitionlayer laminate web may be in an intimate contact with each other.

The maximum interior width of the void area at the distal portion may begreater than the protrusion base width of the base of the majority ofthe three-dimensional protrusions. Measurements of the protrusion basewidth of the base or the maximum interior width of the void area at thedistal portion can be made on a photomicrograph at 20× magnification.

The fibers of the topsheet and acquisition layer in the area of thethree-dimensional protrusions of the topsheet/acquisition layer laminatemay substantially or completely surround the one or more side walls ofthe majority of the three-dimensional protrusions.

The majority of the three-dimensional protrusions may be configured tocollapse in a controlled manner such that each base forming an openingremains open, and the protrusion base width of each base forming anopening is greater than 0.5 mm after compression according toAccelerated Compression Method.

The width of the acquisition layer of the topsheet/acquisition layerlaminate may not wider more than 40% of the width of the distributionlayer and/or more than 20% of the width of the absorbent core.

The absorbent article may comprise gasketing cuffs.

The majority of the three-dimensional protrusions of thetopsheet/acquisition layer laminate may at least or only be present inthe area where the topsheet overlaps the acquisition layer in thetopsheet/acquisition layer laminate.

The majority of the three-dimensional protrusions of thetopsheet/acquisition layer laminate may be present in the area whichextends parallel to the transversal axis of the absorbent article. Themajority of the three-dimensional protrusions of thetopsheet/acquisition layer laminate may be present in the area whichextends parallel to the longitudinal axis of the absorbent article, butwhich does not extend beyond the area where gasketing cuffs is attachedto the absorbent article. In that case, the three-dimensionalprotrusions which are formed in the topsheet of the topsheet/acquisitionlayer laminate, are formed from the fibers of the topsheet.

The majority of the three-dimensional protrusions of thetopsheet/acquisition layer laminate may protrude towards the backsheet.The majority of the three-dimensional protrusions of thetopsheet/acquisition layer laminate may comprise a distal end in contactwith the second surface of the carrier layer. The second surface of thecarrier layer may be attached to the distal ends of the majority of thethree-dimensional protrusions of the topsheet/acquisition layerlaminate.

The topsheet/acquisition layer laminate web may comprise a plurality ofthree-dimensional protrusions protruding towards the backsheet web ortowards the body of the wearer when the absorbent article is in use.

The process may comprise the step of providing the topsheet web with afirst region of the topsheet and the acquisition layer with a firstregion of the acquisition layer; wherein the concentration of fibers inthe first region of the acquisition layer and in the distal ends of themajority of the three dimensional protrusions is greater than theconcentration of fibers in the side walls of the majority of the threedimensional protrusions in the acquisition layer; and wherein theconcentration of fibers in the first region of the topsheet and in thedistal ends of the majority of the three dimensional protrusions isgreater than the concentration of fibers in the side walls of themajority of the three dimensional protrusions in the topsheet.

The process may comprise the step of providing the topsheet web with afirst region of the topsheet and the acquisition layer with a firstregion of the acquisition layer; wherein the concentration of fibers inthe first region of the acquisition layer is greater than theconcentration of fibers in the distal ends of the majority of the threedimensional protrusions in the acquisition layer; and wherein theconcentration of fibers in the first region of the topsheet and thedistal ends of the majority of the three dimensional protrusions isgreater than the concentration of fibers in the side walls of themajority of the three dimensional protrusions in the topsheet.

The process may comprise the step of providing the topsheet web with afirst region of the topsheet and the acquisition layer with a firstregion of the acquisition layer; wherein the concentration of fibers inthe first region of the acquisition layer is greater than theconcentration of fibers in the side walls of the majority of the threedimensional protrusions in the acquisition layer; and wherein theconcentration of fibers in the side walls of the majority of the threedimensional protrusions in the acquisition layer is greater than theconcentration of fibers forming the distal ends of the majority of thethree dimensional protrusions in the acquisition layer.

The process according may comprise the step of applying an indicia tothe topsheet web, the acquisition layer, and/or the carrier layer web.

The process may comprise the step of printing an indicia on the topsheetweb, the acquisition layer, and/or the carrier layer web.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the present invention, it is believed that thesame will be better understood from the following description read inconjunction with the accompanying drawings in which:

FIG. 1 is an absorbent article in the form of a diaper comprising anexemplary topsheet/acquisition layer laminate wherein the length of theacquisition layer is less that the length of the topsheet according tothe present invention with some layers partially removed;

FIG. 2 is a transversal cross-section of the diaper of FIG. 1;

FIG. 3 is a transversal cross-section of the diaper of FIG. 1;

FIG. 4 is an absorbent article in the form of a diaper comprising anexemplary topsheet/acquisition layer laminate wherein thethree-dimensional protrusions of the topsheet/acquisition layer laminateare only formed where the topsheet overlaps the acquisition layer in thetopsheet/acquisition layer laminate, according to the present inventionwith some layers partially removed;

FIG. 5 is an absorbent article in the form of a diaper comprising anexemplary topsheet/acquisition layer laminate with another type ofabsorbent core according to the present invention with some layerspartially removed;

FIG. 6 is a transversal cross-section of a diaper of FIG. 5;

FIG. 7 is a transversal cross-section of the absorbent article of FIG. 5taken at the same point as FIG. 6 where channels have formed as a resultthe absorbent article being loaded with liquid bodily exudates;

FIG. 8 is a side schematic view of an example of a process according tothe present invention;

FIG. 9 is a side schematic view of another example of a processaccording to the present invention;

FIG. 10 is a side schematic view of another example of a processaccording to the present invention;

FIG. 11 is an absorbent article in the form of a diaper comprising anexemplary topsheet/acquisition layer laminate with a carrier layeraccording to the present invention with some layers partially removed;

FIG. 12A is a transversal cross-section of the diaper of FIG. 11;

FIG. 12B is another transversal cross-section of the diaper of FIG. 11;

FIG. 13 is an absorbent article in the form of a diaper comprising anexemplary topsheet/acquisition layer laminate with a carrier layeraccording to the present invention with some layers partially removed;

FIG. 14 is a transversal cross-section of the diaper of FIG. 13;

FIG. 15 is an absorbent article in the form of a diaper comprising anexemplary topsheet/acquisition layer laminate with an acquisition layerpositioned in a front region of the absorbent article according to thepresent invention with some layers partially removed;

FIG. 16 is an absorbent article in the form of a diaper comprising anexemplary topsheet/acquisition layer laminate with an acquisition layerpositioned in a rear region of the absorbent article according to thepresent invention with some layers partially removed;

FIG. 17A is a perspective view of an apparatus comprising a first andsecond forming member for forming the topsheet/acquisition layerlaminate web of the present invention;

FIG. 17B is a perspective view of a portion of the first forming memberof the apparatus shown in FIG. 17A;

FIG. 17C is a perspective view of the apparatus shown in FIG. 17A,showing the first forming member intermeshing the second forming member;

FIG. 18A is a perspective view of a three-dimensional protrusion of thetopsheet/acquisition layer laminate obtained with the apparatus shown inFIG. 17A;

FIG. 18B is a schematic view of a three-dimensional protrusion of thetopsheet/acquisition layer laminate obtained with the apparatus shown inFIG. 17A;

FIG. 18C is a schematic view of a three-dimensional protrusion of thetopsheet/acquisition layer laminate obtained with the apparatus shown inFIG. 17A;

FIG. 18D is a schematic view of a three-dimensional protrusion of thetopsheet/acquisition layer laminate obtained with the apparatus shown inFIG. 17A;

FIG. 18E is a schematic view of a three-dimensional protrusion of thetopsheet/acquisition layer laminate obtained with the apparatus shown inFIG. 17A;

FIG. 18F is a schematic view of a three-dimensional protrusion of thetopsheet/acquisition layer laminate obtained with the apparatus shown inFIG. 17A;

FIG. 19A is a schematic view of a three-dimensional protrusion of thetopsheet/acquisition layer laminate obtained with the apparatus shown inFIG. 17A;

FIG. 19B is a schematic view of a three-dimensional protrusion of thetopsheet/acquisition layer laminate obtained with the apparatus shown inFIG. 17A;

FIG. 19C is a schematic view of a three-dimensional protrusion of thetopsheet/acquisition layer laminate obtained with the apparatus shown inFIG. 17A;

FIG. 19D is a schematic view of a three-dimensional protrusion of thetopsheet/acquisition layer laminate obtained with the apparatus shown inFIG. 17A;

FIG. 19E is a schematic view of a three-dimensional protrusion of thetopsheet/acquisition layer laminate obtained with the apparatus shown inFIG. 17A.

DETAILED DESCRIPTION OF THE INVENTION Definition of Terms

The term “absorbent article” as used herein refers to disposableproducts such as diapers, pants or feminine hygiene sanitary napkins andthe like which are placed against or in proximity to the body of thewearer to absorb and contain the various liquid bodily exudatesdischarged from the body. Typically these absorbent articles comprise atopsheet, backsheet, an absorbent core and optionally an acquisitionlayer and/or distribution layer and other components, with the absorbentcore normally placed between the backsheet and the acquisition system ortopsheet. The absorbent article of the present invention may be a diaperor pant.

The term “diaper” as used herein refers to an absorbent article that isintended to be worn by a wearer about the lower torso to absorb andcontain liquid bodily exudates discharged from the body. Diapers may beworn by infants (e.g. babies or toddlers) or adults. They may beprovided with fastening elements.

The term “pant” as used herein refers to an absorbent article havingfixed edges, a waist opening and leg openings designed for infant oradult wearers. A pant is placed in position on the wearer by insertingthe wearer's legs into the leg openings and sliding the pant-typeabsorbent article into position about the wearer's lower torso. A pantmay be preformed by any suitable technique including, but not limitedto, joining together portions of the absorbent article usingrefastenable and/or non-refastenable bonds (e.g., seam, weld, adhesive,cohesive bond, fastener, etc.). A pant may be preformed anywhere alongthe circumference of the article (e.g., side fastened, front waistfastened).

The term “extensible” as used herein refers to a material, which, uponapplication of a force, is capable of undergoing an apparent elongationof equal to or greater than at least 100% of its original length in themachine and/or cross-machine directions at or before reaching thebreaking force if subjected to the following test:

The MD and CD tensile properties are measured using a method using WSP110.4 (05) Option B, with a 50 mm sample width, 60 mm gauge length, and60 mm/min rate of extension.

It may be desirable that a material is capable of undergoing an apparentelongation of equal to or greater than at least 100% or 110% or 120% or130% up to 200% in the machine and/or cross-machine directions at orbefore reaching the breaking force according to the Test Method as setout above.

If a material is capable of undergoing an apparent elongation of lessthan 100% of its original length if subjected to the above describedtest, it is “non-extensible” as used herein.

The term “topsheet/acquisition layer laminate web” as used herein refersto an intimate combination of a topsheet web with an acquisition layer,both disposed in a face to face relationship. The topsheet web has afirst and second surface. The first surface of the topsheet web isfacing towards the body of the wearer when the absorbent article is inuse. The acquisition layer is facing the backsheet web or the optionaldistribution layer. The topsheet web and the acquisition layer haveundergone a simultaneous and joint mechanical deformation while thetopsheet web and the acquisition layer are combined with each other. Thetopsheet/acquisition layer laminate web comprises deformations formingthree-dimensional protrusions.

In the topsheet/acquisition layer laminate web, the topsheet web andacquisition layer may be in an intimate contact with each other.

The topsheet/acquisition layer laminate web may be formed by nestingtogether the topsheet web and acquisition layer, wherein thethree-dimensional protrusions of the topsheet web coincide with and fittogether with the three-dimensional protrusions of the acquisitionlayer, as shown in FIGS. 18B and 19A. The topsheet web and acquisitionlayer may be both extensible such that the topsheet web and acquisitionlayer are able to stretch.

Alternatively or in addition to what has been set out above, thetopsheet/acquisition layer laminate web may be formed by interruptingone of the topsheet web or acquisition layer such that thethree-dimensional protrusions of the respective other non-interruptedtopsheet web or acquisition layer interpenetrate the interruptedtopsheet web or acquisition layer, as shown in FIGS. 18C and 19B.

In still another alternative or in addition to what has been set outabove, the topsheet/acquisition layer laminate web may be formed byinterrupting one of the topsheet web or acquisition layer in the area ofthe three-dimensional protrusions of the topsheet/acquisition layerlaminate web such that the three-dimensional protrusions of therespective other non-interrupted topsheet web or acquisition layer atleast partially fit together with the three-dimensional protrusions ofthe interrupted topsheet web or acquisition layer, as shown in FIGS.18D, 18E, 19C and 19D.

In another alternative or in addition to what has been set out above,the topsheet/acquisition layer laminate web may be formed byinterrupting the topsheet web and acquisition layer in the area of thethree-dimensional protrusions of the topsheet/acquisition layer laminateweb and the three-dimensional protrusions of the topsheet web coincidewith and fit together with the three-dimensional protrusions of theacquisition layer. If the topsheet web and acquisition layer compriseinterruptions in the area of the three-dimensional protrusions, theinterruptions in the topsheet web in the area of the three-dimensionalprotrusions of the topsheet/acquisition layer laminate web will notcoincide with the interruptions in the acquisition layer in the area ofthe three-dimensional protrusions of the topsheet/acquisition layerlaminate web, as shown in FIGS. 18F and 19E.

The terms “interruptions”, as used herein, refer to holes formed in thetopsheet web and/or acquisition layer during the formation of thetopsheet/acquisition layer laminate web, and does not include the poresand interstices between fibers typically present in nonwovens.

The term “mechanically deforming and combining” as used herein meansthat the topsheet web and acquisition layer are put in a face to facerelationship and are simultaneously mechanically deformed between afirst and second roll and intimately combined at the same time. Themechanical deformation of the topsheet web and acquisition layer dependson the process, the required apparatus but also on the properties of thetopsheet web and acquisition layer, i.e. apparent elongation of thefibers, fiber mobility, ability to deform and stretch in the area wherethe three-dimensional protrusions of the topsheet/acquisition layerlaminate web are formed, ability to undergo plastic deformation whichsets after existing the first and second roll, or springing partiallyback due to elastic recovery.

The mechanical deformation may comprise engaging the topsheet web andthe acquisition layer together between a first and second forming membersuch that a plurality of deformations comprising three-dimensionalprotrusions are obtained. The three-dimensional protrusions are formedform the fibers of the topsheet web and the acquisition layer. Amajority of the three-dimensional protrusions is defined by a baseforming an opening, an opposed distal portion and the one or more sidewall between the base and the distal portion of the majority of thethree-dimensional protrusions. The base, distal portion and one or moreside wall are formed by fibers such that the majority of thethree-dimensional protrusions has only an opening at the base, as shownin FIG. 18A.

The term “topsheet/acquisition layer laminate” as used herein refers toan intimate combination of a topsheet with an acquisition layer, bothdisposed in a face to face relationship. The topsheet has a first andsecond surface. The first surface of the topsheet is facing towards thebody of the wearer when the absorbent article is in use. The acquisitionlayer is facing the backsheet or the optional distribution layer. Thetopsheet and the acquisition layer have undergone a simultaneous andjoint mechanical deformation while the topsheet and the acquisitionlayer are combined with each other. The topsheet/acquisition layerlaminate comprises deformations forming three-dimensional protrusions.

For the majority of the three-dimensional protrusions of the resultingtopsheet/acquisition layer laminate:

-   -   The topsheet may be nested into the acquisition layer or vice        versa such that the three-dimensional protrusions of the        topsheet and of the acquisition layer coincide with and fit        together, as shown in FIGS. 18B and 19A.    -   Alternatively or in addition to what has been set out above, one        of the topsheet or acquisition layer may be interrupted in the        area of the three-dimensional protrusions of the        topsheet/acquisition layer laminate such that the        three-dimensional protrusions made of the respective other        non-interrupted topsheet or acquisition layer interpenetrate the        interruptions of the topsheet or of the acquisition layer, as        shown in FIGS. 18C and 19B.    -   Alternatively or in addition to what has been set out above, one        of the topsheet or acquisition layer may be interrupted in the        area of the three-dimensional protrusions of the        topsheet/acquisition layer laminate such that the        three-dimensional protrusions made of the respective other        non-interrupted topsheet or acquisition layer at least partially        fit together with the three-dimensional protrusions of the        interrupted topsheet or of the interrupted acquisition layer, as        shown in FIGS. 18D, 18E, 19C and 19D.    -   Alternatively or in addition to what has been set out above, the        topsheet and acquisition layer may be interrupted in the area of        the three-dimensional protrusions of the topsheet/acquisition        layer laminate and the three-dimensional protrusions of the        topsheet coincide with and fit together with the        three-dimensional protrusions of the acquisition layer. The        interruptions in the topsheet in the area of the        three-dimensional protrusions of the topsheet/acquisition layer        laminate may not coincide with the interruptions in the        acquisition layer in the area of the three-dimensional        protrusions of the topsheet/acquisition layer laminate, as shown        in FIGS. 18F and 19E.

The term “a majority of the three-dimensional protrusions” as usedherein means that more than 50% or more than 60% or more than 70% ormore than 80% or more than 90% or more than 95% or more than 98% of thethree-dimensional protrusions in the topsheet/acquisition layer laminateweb or in the topsheet/acquisition layer laminate of the absorbentarticle, each comprises a base forming an opening, an opposed distalportion and the one or more side wall between the base and the distalportion of the three-dimensional protrusion. The base, distal portionand one or more side wall are formed by fibers such that thethree-dimensional protrusion has only an opening at the base (asexemplary shown in a FIG. 18A).

The term “machine direction” or “MD” as used herein means the path thatmaterial, such as a web, follows through a manufacturing process.

The term “cross-machine direction” or “CD” as used herein means the paththat is perpendicular to the machine direction in the plane of the web.

The term “cellulosic fiber” as used herein refers to natural fiberswhich typically are wood pulp fibers. Applicable wood pulps includechemical pulps, such as Kraft, sulfite, and sulfate pulps, as well asmechanical pulps including, for example, groundwood, thermomechanicalpulp and chemically modified thermomechanical pulp. Pulps derived fromboth deciduous trees (hereinafter, also referred to as “hardwood”) andconiferous trees (hereinafter, also referred to as “softwood”) may beutilized. The hardwood and softwood fibers can be blended, oralternatively, can be deposited in layers to provide a stratified web.

The term “dry-laid fiber” as used herein means fibers which have beenprovided in a fluid medium which is gaseous (air).

The term “wet-laid fiber” as used herein comprises cellulosic fiberswhich have been suspended in an aqueous medium, such as water, beforebeing converted into a web and dried according to a wet-laid papermakingprocess.

The term “web” as used herein means a material capable of being woundinto a roll. Webs may be nonwovens.

The term “nonwoven web” as used herein refers to a manufacturedmaterial, web, sheet or batt of directionally or randomly orientedfibers, bonded by friction, and/or cohesion and/or adhesion, excludingpaper and products which are woven, knitted, tufted, stitch-bonded,incorporating binding yarns or filaments, or felted by wet milling,whether or not additionally needled. The fibers may be of natural orman-made origin. The fibers may be staple or continuous filaments or beformed in situ. The porous, fibrous structure of a nonwoven may beconfigured to be liquid permeable or impermeable, as desired.

The term “absorbent core” as used herein refers to a component, which isplaced or is intended to be placed within an absorbent article and whichcomprises an absorbent material enclosed in a core wrap. The term“absorbent core” does not include an acquisition or distribution layeror any other component of an absorbent article which is not either anintegral part of the core wrap or placed within the core wrap. Theabsorbent core is typically the component of an absorbent article whichcomprises all, or at least the majority of, superabsorbent polymer andhas the highest absorbent capacity of all the components of theabsorbent article.

The term “substantially free of absorbent material” or “substantiallyabsorbent material free” as used herein means that the basis weight ofthe absorbent material in the substantially absorbent material freeareas is at least less than 10%, in particular less than 5%, or lessthan 2%, of the basis weight of the absorbent material in the rest ofthe absorbent core.

The term “superabsorbent polymers” (herein abbreviated as “SAP”) as usedherein refer to absorbent materials which are cross-linked polymericmaterials that can absorb at least 10 times their weight of an aqueous0.9% saline solution as measured using the Centrifuge Retention Capacity(CRC) test (EDANA method WSP 241.2-05E). The SAP of the invention may inparticular have a CRC value of more than 20 g/g, or more than 25 g/g, orfrom 20 to 50 g/g, or from 20 to 40 g/g, or 25 to 35 g/g. The SAP usefulin the invention includes a variety of water-insoluble, butwater-swellable polymers capable of absorbing large quantities of liquidbodily exudates.

The term “joined to” as used herein encompasses configurations in whichan element is directly secured to another element by affixing theelement directly to the other element; and configurations in which theelement is indirectly secured to the other element by affixing theelement to intermediate member(s) which in turn are affixed to the otherelement. The term “joined to” encompasses configurations in which anelement is secured to another element at selected locations, as well asconfigurations in which an element is completely secured to anotherelement across the entire surface of one of the elements. The term“joined to” includes any known manner in which elements can be securedincluding, but not limited to mechanical entanglement.

The term “joined adjacent to the transversal edges” as used herein meansthat when a first and/or second transversal edge of a first layer is/arejoined adjacent to a first and/or second transversal edges of a secondlayer, the first and/or second transversal edge of the first layer aredisposed within an area spaced inboard from the first and/or secondtransversal edge of the second layer. The area has a width which is from1 to 30% of the width of the second layer.

“Comprise,” “comprising,” and “comprises” are open ended terms, eachspecifies the presence of the feature that follows, e.g. a component,but does not preclude the presence of other features, e.g. elements,steps, components known in the art or disclosed herein. These termsbased on the verb “comprise” should be read as encompassing the narrowerterms “consisting essential of” which excludes any element, step oringredient not mentioned which materially affect the way the featureperforms its function, and the term “consisting of” which excludes anyelement, step, or ingredient not specified. Any preferred or exemplaryembodiments described below are not limiting the scope of the claims,unless specifically indicated to do so. The words “typically”,“normally”, “advantageously” and the likes also qualify features whichare not intended to limit the scope of the claims unless specificallyindicated to do so.

General Description of the Absorbent Article 20

An exemplary absorbent article 20 in which the absorbent core 28 of theinvention can be used is a taped diaper 20 as represented in FIG. 1;FIG. 4 and FIG. 5 with a different absorbent core construction. FIG. 1;FIG. 4 and FIG. 5 are top plan views of the exemplary diaper 20, in aflat-out state, with portions of the structure being cut-away to moreclearly show the construction of the diaper 20. This diaper 20 is shownfor illustration purpose only as the invention may be used for making awide variety of diapers or other absorbent articles.

The absorbent article 20 comprises a topsheet/acquisition layer laminate245 formed from a liquid permeable topsheet 24 and an acquisition layer52. In other words, the absorbent article 20 comprises a liquidpermeable topsheet 24 and an acquisition layer 52 characterized in thatthe topsheet 24 and acquisition layer 52 are joined to form atopsheet/acquisition layer laminate 245. The absorbent article 20comprises a liquid impermeable backsheet 25 and an absorbent core 28between the topsheet 24 and the backsheet 25. The absorbent article 20comprises a front edge 10, a back edge 12, and two longitudinal sideedges 13. The front edge 10 is the edge of the absorbent article 20which is intended to be placed towards the front of the user when worn,and the back edge 12 is the opposite edge. The absorbent article 20 maybe notionally divided by a longitudinal axis 80 extending from the frontedge 10 to the back edge 12 of the absorbent article 20 and dividing theabsorbent article 20 in two substantially symmetrical halves relative tothis axis, when viewing the absorbent article 20 from the wearer facingside in a flat out configuration, as exemplarily shown in FIG. 1, FIG. 4and FIG. 5.

The absorbent article 20 may comprise a distribution layer 54 which maycomprise a dry-laid fibrous structure or wet-laid fibrous structure. Thetopsheet/acquisition layer laminate 245 is facing towards the body ofthe wearer when the absorbent article 20 is in use.

The wet-laid fibrous structure comprising wet-laid fibers may have a Wetburst Strength from 50 to 500 g according to the Wet Burst Strength TestMethod and combinations thereof.

The distribution layer 54 may comprise a dry-laid fibrous structure. Thedry-laid fibrous structure may comprise dry-laid fibers. The dry-laidfibrous structure may comprise a mixture including superabsorbentpolymers and dry-laid fibers. The dry-laid fibers may compriseintra-fiber cross-linked cellulosic fibers.

The distribution layer 54 may comprise a wet-laid fibrous structure. Thewet-laid fibrous structure may comprise wet-laid fibers.

The distribution layer 54 may have an average basis weight of from 30 to400 gsm, in particular from 100 to 300 gsm or from 50 to 250 gsm.

As explained more in a process detailed below, a topsheet web 240 and anacquisition layer 52 are simultaneously mechanically deformed andcombined together to form a topsheet/acquisition layer laminate web2450. The topsheet/acquisition layer laminate web 2450 forms thetopsheet/acquisition layer laminate 245 in the absorbent article 20. Thetopsheet/acquisition layer laminate 245 comprises mechanicaldeformations forming three-dimensional protrusions 250. The mechanicaldeformations provide a three-dimensional structure to thetopsheet/acquisition layer laminate 245.

The absorbent article 20 may comprise elasticized gasketing cuffs 32present between the topsheet 24 and the backsheet 25 and upstandingbarrier leg cuffs 34. FIGS. 1, 4 and 5 also show other typical diapercomponents such as a fastening system comprising fastening tabs 42attached towards the back edge 12 of the absorbent article 20 andcooperating with a landing zone 44 towards the front edge 10 of theabsorbent article 20. The absorbent article 20 may also comprise othertypical components, which are not represented in the Figures, such as aback elastic waist feature, a front elastic waist feature, transversebarrier cuff(s), a lotion application, etc. As shown in FIG. 7, thebarrier leg cuffs 34 may be delimited by a proximal edge 64 joined tothe rest of the absorbent article 20, typically the topsheet 24 and/orthe backsheet 25, and a free terminal edge intended to contact and forma seal with the wearer's skin. The barrier leg cuffs 34 may be joined atthe proximal edge 64 by a bond 65 which may be made for example byadhesive bonding, fusion bonding or combination of known bonding means.Each barrier leg cuff 34 may comprise one, two or more elastic strings35 to provide a better seal. The gasketing cuffs 32 may be placedlaterally outwardly relative to the barrier leg cuffs 34. The gasketingcuffs 32 can provide a better seal around the thighs of the wearer.Usually each gasketing leg cuff 32 will comprise one or more elasticstring or elastic element 33 for example between the topsheet 24 and thebacksheet 25 in the area of leg openings.

The absorbent article 20 can also be notionally divided by a transversalaxis 90 in a front region and a back region of equal length measured onthe longitudinal axis, when the absorbent article 20 is in a flat state.The absorbent article's transversal axis 90 is perpendicular to thelongitudinal axis 80 and placed at half the length of the absorbentarticle 20. The length of the absorbent article 20 can be measured alongthe longitudinal axis 80 from the front edge 10 to the back edge 12 ofthe absorbent article 20. The topsheet 24, acquisition layer 52,distribution layer 54 and absorbent core 28 each have a width which canbe measured from their respective transversal edges and in parallel tothe transversal axis 90.

The absorbent article 20 is notionally divided in a front region 36, aback region 38 and a crotch region 37 located between the front and theback region of the absorbent article 20. Each of the front, back andcrotch region is ⅓ of the length of the absorbent article 20. Theabsorbent article may also comprise front ears 46 and back ears 40 as itis known in the art.

The absorbent core 28 of the present invention may comprise as absorbentmaterial 60 a blend of cellulosic fibers (so called “airfelt”) andsuperabsorbent polymers in particulate form encapsulated in one or moresubstrates, see for example U.S. Pat. No. 5,151,092 (Buell).Alternatively, the absorbent core 28 may be airfelt free as described indetail below.

Generally, the absorbent core 28 can be defined by the periphery of thelayer formed by the absorbent material 60 within the core wrap 160, asseen from the top side of the absorbent core 28. The absorbent core 28can take various shapes, in particular display a so-called “dog bone” or“hour-glass” shape, which shows a tapering along its width towards themiddle or “crotch” region of the core. In this way, the absorbent core28 may have a relatively narrow width in an area of the absorbent core28 intended to be placed in the crotch region of the absorbent article.This may provide for example better wearing comfort. The absorbent core28 may thus have a width (as measured in the transversal direction) atits narrowest point which is less than about 100 mm, 90 mm, 80 mm, 70mm, 60 mm or even less than about 50 mm. The absorbent core 28 can alsobe generally rectangular, see for example as shown in FIG. 5, but otherdeposition areas can also be used such as a “T” or “Y” or “hour-glass”or “dog-bone” shape (See for example FIG. 4).

Some components of the absorbent article 20 will now be discussed inmore details.

“Airfelt-Free” Absorbent Core 28

The absorbent core 28 of the invention may comprise an absorbentmaterial 60 enclosed within a core wrap 160. The absorbent material 60may comprise from 80% to 100% of SAP, such as SAP particles, by totalweight of the absorbent material 60. The core wrap 160 is not consideredas an absorbent material 60 for the purpose of assessing the percentageof SAP in the absorbent core 28.

By “absorbent material” it is meant a material which has at least someabsorbency and/or liquid retaining properties, such as SAP, cellulosicfibers as well as some hydrophilically treated synthetic fibers.Typically, adhesives used in making absorbent cores have no absorbencyproperties and are not considered as absorbent material. The SAP contentmay be substantially higher than 80%, for example at least 85%, at least90%, at least 95% and even up to and including 100% of the weight of theabsorbent material 60 contained within the core wrap 160. This above SAPcontent substantially higher than 80% SAP may provide a relatively thinabsorbent core 28 compared to conventional absorbent cores typicallycomprising between 40-60% SAP and 40-60% of cellulosic fibers. Theabsorbent material 60 of the invention may in particular comprise lessthan 10% weight percent, or less than 5% weight percent, or even besubstantially free of natural and/or synthetic fibers. The absorbentmaterial 60 may advantageously comprise little or no cellulosic fibers,in particular the absorbent core 28 may comprise less than 15%, 10%, or5% (airfelt) cellulosic fibers by weight of the absorbent core 28, oreven be substantially free of cellulose fibers. Such absorbent core 28may be relatively thin and thinner than conventional airfelt cores. FIG.1, FIG. 2 and FIG. 3 are illustrations of an absorbent article 20comprising an “airfelt-free” absorbent core 28.

“Airfelt-free” absorbent cores 28 comprising relatively high amount ofSAP with various absorbent core designs have been proposed in the past,see for example in U.S. Pat. No. 5,599,335 (Goldman), EP1447066A1(Busam), WO95/11652 (Tanzer), US2008/0312622A1 (Hundorf), andWO2012/052172 (Van Malderen).

The absorbent core 28 of the invention may comprise adhesive for exampleto help immobilizing the SAP within the core wrap 160 and/or to ensureintegrity of the core wrap 160 in particular when the core wrap 160 ismade of one or more substrates. The core wrap 160 will typically extendover a larger area than strictly needed for containing the absorbentmaterial 60 within.

Core Wrap

The absorbent material 60 is encapsulated in one or more substrates. Thecore wrap 160 comprises a top side 16 facing the topsheet 24 and abottom side 16′ facing the backsheet 25. The core wrap 160 may be madeof a single substrate folded around the absorbent material 60. The corewrap 160 may be made of two substrates (one mainly providing the topside 16 and the other mainly providing the bottom side 16′) which areattached to another, as exemplarily shown in FIG. 2. Typicalconfigurations are the so-called C-wrap and/or sandwich wrap. In aC-wrap, as exemplarily shown in FIG. 6, the longitudinal and/ortransversal edges of one of the substrate are folded over the othersubstrate to form flaps. These flaps are then bonded to the externalsurface of the other substrate, typically by bonding with an adhesive.The so called C-wrap construction can provide benefits such as improvedresistance to bursting in a wet loaded state compared to a sandwichseal.

The core wrap 160 may be formed by any materials suitable for receivingand containing the absorbent material 60. The core wrap 160 may inparticular be formed by a nonwoven web, such as a carded nonwoven,spunbond nonwoven (“S”) or meltblown nonwoven (“M”), and laminates ofany of these. For example spunmelt polypropylene nonwovens are suitable,in particular those having a laminate web SMS, or SMMS, or SSMMS,structure, and having a basis weight range of about 5 gsm to 15 gsm.Suitable materials are for example disclosed in U.S. Pat. No. 7,744,576,US2011/0268932A1, US2011/0319848A1 or US2011/0250413A1. Nonwovenmaterials provided from synthetic fibers may be used, such aspolyethylene (PE), polyethylene terephthalate (PET) and in particularpolypropylene (PP).

“Airfelt-Free” Absorbent Core 28 Comprising Substantially AbsorbentMaterial Free Areas 26

The absorbent core 28 may comprise an absorbent material deposition area8 defined by the periphery of the layer formed by the absorbent material60 within the core wrap 160.

The absorbent core 28 may comprise one or more substantially absorbentmaterial free area(s) 26 which is/are substantially free of absorbentmaterial 60 and through which a portion of the top side 16 of the corewrap 160 is attached by one or more core wrap bond(s) 27 to a portion ofthe bottom side 16′ of the core wrap 160, as shown in FIGS. 5 and 6. Inparticular, there can be no absorbent material 60 in these areas.Minimal amount such as contaminations with absorbent material 60 thatmay occur during the making process are not considered as absorbentmaterial 60. The one or more substantially absorbent material freearea(s) 26 may be advantageously confined by the absorbent material 60,which means that the substantially absorbent material free area(s) 26do(es) not extend to any of the edge of the absorbent materialdeposition area 8.

If the substantially absorbent material free area 26 extends to any ofthe edges of the absorbent material deposition area 8, eachsubstantially absorbent material free area 26 may have areas ofabsorbent material 60 on either side of each substantially absorbentmaterial free area 26.

The absorbent core 28 may comprise at least two substantially absorbentmaterial free areas 26 symmetrically disposed on both sides of thelongitudinal axis of the absorbent core 28, as shown in FIG. 5.

The substantially absorbent material free area(s) 26 may be straight andcompletely oriented longitudinally and parallel to the longitudinal axisbut also may be curved or have one or more curved portions.

Furthermore, in order to reduce the risk of liquid bodily exudateleakages, the substantially absorbent material free area(s) 26advantageously do not extend up to any of the edges of the absorbentmaterial deposition area 8, and are therefore surrounded by and fullyencompassed within the absorbent material deposition area 8 of theabsorbent core 28. Typically, the smallest distance between asubstantially absorbent material free area 26 and the closest edge ofthe absorbent material deposition area 8 is at least 5 mm.

“Airfelt free” absorbent cores 28 comprising substantially absorbentmaterial free areas 26 have been proposed, see for example in EP PatentApplication No. 12196341.7.

One or more channel(s) 26′ along the substantially absorbent materialfree area(s) 26 in the absorbent core 28 may start forming when theabsorbent material 60 absorbs a liquid and starts swelling. As theabsorbent core 28 absorbs more liquid, the depressions within theabsorbent core 28 formed by the channel(s) 26′ will become deeper andmore apparent to the eye and the touch. The formation of the channel(s)26′ may also serve to indicate that the absorbent article 20 has beenloaded with liquid bodily exudates. The core wrap bond(s) 27 shouldremain substantially intact at least during a first phase as theabsorbent material 60 absorbs a moderate quantity of liquid bodilyexudates.

As shown in FIG. 7, when the absorbent material swells, the core wrapbonds 27 remain at least initially attached in the substantiallyabsorbent material free areas 26. The absorbent material 60 swells inthe rest of the absorbent core 28 when it absorbs a liquid, so that thecore wrap thus forms channels 26′ along the substantially absorbentmaterial free areas 26 comprising the core wrap bonds 27.

The Process of Making the Absorbent Article Having aTopsheet/Acquisition Layer Laminate Web

A topsheet/acquisition layer laminate 245 having a three-dimensionalstructure is provided.

A process 100 of making an absorbent article 20 comprises the step ofproviding a liquid permeable topsheet web 240 extending substantiallycontinuously in a machine direction, the topsheet web 240 having a firstand second surface, a liquid impermeable backsheet web 2555 extendingsubstantially continuously in the machine direction, and an acquisitionlayer 52 having a first and second surface. In an absorbent article 20,the first surface of the topsheet 24 will be facing towards the body ofthe wearer when the absorbent article 20 is in use. The topsheet web 240and thus the topsheet 24 and the acquisition layer 52 comprise fibers.

The topsheet web 240 and acquisition layer 52 are aligned in a face toface relationship such that the second surface of the topsheet web 240is in contact with the first surface of the acquisition layer 52. Thetopsheet web 240 and the acquisition layer 52 are simultaneouslymechanically deformed and combined together to provide atopsheet/acquisition layer laminate web 2450 having three-dimensionalprotrusions 250. This means that both topsheet web 240 and acquisitionlayer 52 are mechanically deformed and combined together at the sametime.

The three-dimensional protrusions 250 are formed from the fibers of thetopsheet web 240 and the acquisition layer 52. A majority of thethree-dimensional protrusions 250 each comprises a base 256 forming anopening and having a protrusion base width, an opposed distal portion257, and one or more side walls 255 between the base 256 and the distalportion 257 of the majority of the three-dimensional protrusions. Thebase 256, distal portion 257 and the one or more side walls 255 areformed by fibers such that the majority of the three-dimensionalprotrusions 250 has only an opening at the base, as e.g. shown in FIG.18A. The majority of the three-dimensional protrusions 250 can beobtained by the mechanical process described in detail below.

The majority of the three-dimensional protrusions 250 may be more than50% or more than 60% or more than 70% or more than 80% or more than 90%or more than 95% or more than 98% of the three-dimensional protrusions250 in the topsheet/acquisition layer laminate web 2450 or in thetopsheet/acquisition layer laminate 245.

The fibers may substantially or completely surround the one or more sidewalls 255 of the majority of the three-dimensional protrusions 250. Thismeans that there are multiple fibers which contribute to form a portionof the side walls 255 and distal portion 257 of a three-dimensionalprotrusion 250. The term “substantially surround” does not require thateach individual fiber be wrapped substantially or completely around theside walls 255 of the majority of the three-dimensional protrusions 250.

The topsheet/acquisition layer laminate web 2450 has a first surfacecomprising the second surface of the acquisition layer 52.

A portion of the backsheet web 2555 is joined to a portion of thetopsheet web 240 of the topsheet/acquisition layer laminate web 2450such that the first surface of the topsheet/acquisition layer laminate2450 is facing towards the backsheet web 2555.

The process 100 of making an absorbent article 20 may comprise the stepof providing a dry-laid fibrous structure or a wet-laid fibrousstructure, as shown in FIG. 8.

As shown in FIG. 8, the topsheet web 240 and acquisition layer 52 aremechanically deformed and combined between a first and second roll (211,212) to form a topsheet/acquisition layer laminate web 2450. Dry-laidfibers 540 of a dry-laid fibrous structure (as shown in FIG. 8, providedfrom a distribution material feeder 210) or a wet-laid fibrous structuremay be deposited on the first surface of the topsheet/acquisition layerlaminate web 2450 or the backsheet web 2555.

A portion of the backsheet web 2555 may be joined to a portion of thetopsheet web 240 of the topsheet/acquisition layer laminate web 2450such that the dry-laid fibrous structure or the wet-laid fibrousstructure are between the topsheet/acquisition layer laminate web 2450and the backsheet web 2555.

The dry-laid fibrous structure may comprise dry-laid fibers. Thedry-laid fibrous structure may comprise a mixture includingsuperabsorbent polymers (SAP) and dry-laid fibers. The dry-laid fibersmay comprise intra-fiber cross-linked cellulosic fibers.

The distribution layer may be free of tow fibers.

The distribution layer 54 may for example comprise at least 50% byweight of cross-linked cellulose fibers. The cross-linked cellulosicfibers may be crimped, twisted, or curled, or a combination thereofincluding crimped, twisted, and curled. This type of material has beenused in the past in disposable diapers as part of an acquisition system,for example US 2008/0312622 A1 (Hundorf).

Exemplary chemically cross-linked cellulosic fibers suitable for adistribution layer 54 are disclosed in U.S. Pat. No. 5,549,791; U.S.Pat. No. 5,137,537; WO95/34329 or US2007/118087. Exemplary cross-linkingagents may include polycarboxylic acids such as citric acid and/orpolyacrylic acids such as acrylic acid and maleic acid copolymers.

The distribution layer may typically have an average basis weight offrom 30 to 400 g/m², in particular from 100 to 300 g/m². The density ofthe distribution layer may vary depending on the compression of thearticle, but may be of between 0.03 to 0.15 g/cm³, in particular 0.08 to0.10 g/cm³ measured at 0.30 psi (2.07 kPa).

The process may comprise the step of providing an absorbent core 28which comprises an absorbent material 60. The absorbent material 60 maycomprise from 80% to 100% of SAP, such as SAP particles, by total weightof the absorbent material 60.

Another type of absorbent material may be water-absorbing foams based oncross-linked monomers comprising acid groups, see for example from EP 0858 478 B1, WO 97/31971 A1, WO 99/44648 A1 and WO 00/52087 A1.

Hence, the first surface of the topsheet/acquisition layer laminate web2450 can carry the material of the distribution layer 54 or theabsorbent material 60 of the absorbent core 28.

The absorbent article 20 may comprise gasketing cuffs 32. The majorityof the three-dimensional protrusions 250 of the topsheet/acquisitionlayer laminate 245 may at least be present in the acquisition layer 52and in the topsheet 24, in the area where the topsheet 24 overlaps theacquisition layer 52 in the topsheet/acquisition layer laminate 245.However, the majority of the three-dimensional protrusions 250 of thetopsheet/acquisition layer laminate 245 may be present in the area whichextends parallel to the transversal axis 90 of the absorbent article 20.The majority of the three-dimensional protrusions 250 of thetopsheet/acquisition layer laminate 245 may be present in the area whichextends parallel to the longitudinal axis 80 of the absorbent article20, but which does not extend beyond the area where gasketing cuffs 32is attached to the absorbent article 20, in particular to the topsheet24, as shown in FIG. 2 or 3. In that case, the majority of thethree-dimensional protrusions 250 which are formed in the topsheet 24 ofthe topsheet/acquisition layer laminate 245, are formed from the fibersof the topsheet 24.

Alternatively, the majority of the three-dimensional protrusions 250 ofthe topsheet/acquisition layer laminate 245 may be present in theacquisition layer and in the topsheet in the area which extends parallelto the transversal axis 90 of the absorbent article 20 such that thearea comprising the three-dimensional protrusions of the topsheet 24overlaps the acquisition layer 52. The length of the area of themajority of the three-dimensional protrusions 250 of thetopsheet/acquisition layer 245 may be from 5% to 60% or from 10% to 40%wider than the length of the acquisition layer 52 of thetopsheet/acquisition layer laminate 245. The majority of thethree-dimensional protrusions 250 of the topsheet/acquisition layer 245may be present in the area which extends parallel to the longitudinalaxis 80 of the absorbent article 20 such that the area comprising thethree-dimensional protrusions of the topsheet 24 overlaps theacquisition layer 52. The width of the area of the majority of thethree-dimensional protrusions 250 of the topsheet/acquisition layer 245may be from 5% to 60% or from 10% to 40% wider than the width of theacquisition layer 52 of the topsheet/acquisition layer laminate 245. Inthat case, the majority of the three-dimensional protrusions 250 whichare formed in the topsheet 24 of the topsheet/acquisition layer laminate245, are formed from the fibers of the topsheet 24.

In still another alternative, the majority of the three-dimensionalprotrusions 250 of the topsheet/acquisition layer laminate 245 may onlybe present where the topsheet 24 overlaps the acquisition layer 52 inthe topsheet/acquisition layer laminate 245, as shown in FIG. 4.

Hence, the three-dimensional protrusions 250 can provide an impressionof depth and can support the caregiver's perception that the absorbentarticle 20 is well able to absorb the liquid bodily exudates.

The majority of the three-dimensional protrusions 250 of thetopsheet/acquisition layer laminate 245 may have a measured protrusionheight from 0.3 mm to 5 mm or from 0.5 mm to 3 mm or from 1.0 mm to 2.0mm according to the Protrusion Height Test Method as described below.The majority of the three-dimensional protrusions 250 of thetopsheet/acquisition layer laminate 245 may have a measured protrusionbase width of the three-dimensional protrusions 250 from 0.5 mm to 10 mmor from 0.5 to 5 mm or from 0.5 mm to 3.0 mm or from 1.0 mm to 2.5 mm orfrom 1.5 mm to 2.5 mm according to the Protrusion Base Width Test Methodas described below. The majority of the three-dimensional protrusions250 having a shape with a specific measured protrusion height andmeasured protrusion base width can contribute to provide an impressionof depth and can support the caregiver's perception that the absorbentarticle 20 is well able to absorb the liquid bodily exudates.

These three-dimensional protrusions 250 provide void volume to receivethe liquid bodily exudates. At the same time, the topsheet/acquisitionlayer laminate 245 is in close contact with the underlaying layer, i.e.the distribution layer 54. The distribution layer 54 made ofunconsolidated fibers 540 of the dry-laid fibrous structure or thewet-laid fibrous structure may sink in the depressions provided by thethree-dimensional protrusions 250 of the topsheet/acquisition layerlaminate 245 (not shown in the schematic Figures). The distributionlayer 54 may follow the shape of the three-dimensional protrusions.Hence, the liquid bodily exudates are transmitted more efficiently fromthe topsheet/acquisition layer laminate 245 to the distribution layer54, which can improve the dryness of the topsheet 24 of thetopsheet/acquisition layer laminate 245. Rewet can be reduced at theskin of the wearer. The topsheet/acquisition layer laminate 245 may alsoenable more efficient use of an absorbent core 28. Overall, the topsheet24 of the topsheet/acquisition layer laminate 245 can have an improveddryness than a three-dimensional topsheet 24 placed on top of anacquisition layer 52.

The majority of the three-dimensional protrusions 250 may comprise voidareas 253 which do not contact the skin of the wearer. The absorbentarticle 20 may be in less contact with the skin of the wearer incomparison with a flat topsheet. The void areas 253 of thetopsheet/acquisition layer laminate 245 can help the air to permeatebetween the skin of the wearer and the topsheet/acquisition layerlaminate 245. The void areas 253 of the topsheet/acquisition layerlaminate 245 can improve the breathability of the topsheet/acquisitionlayer laminate 245.

In addition to improve dryness, the void areas 253 of thetopsheet/acquisition layer laminate 245 can also allow feces to beabsorbed and acquired within them. In that case, the present inventionis suitable to absorb feces of relatively low viscosity.

A width of the acquisition layer 52 is less than a width of the topsheetweb 240 in a cross direction. In the absorbent article 20 comprising thelongitudinal axis 80 and the transversal axis 90 perpendicular to thelongitudinal axis 80, the width of the acquisition layer 52 in adirection parallel to the transversal axis 90 is less than the width ofthe topsheet 24 in a direction parallel to the transversal axis 90. Ifthe width of both topsheet 24 and acquisition layer 52 were the same,wicking of the liquid bodily exudates underneath the gasketing cuffs 32might occur. Hence, the liquid bodily exudates might not be properlyabsorbed by the absorbent core 28, which may lead to leakage of theliquid bodily exudates out of the absorbent article 20. If the width ofthe acquisition layer 52 in a direction parallel to the transversal axis90 is less that the width of the topsheet 24 in a direction parallel tothe transversal axis 90, the acquisition layer 52 which may receive theliquid bodily exudates from the topsheet 24 can directly transmit theliquid bodily exudates to the distribution layer 54 in order to besubsequently absorb by the absorbent core 28.

Hence, the liquid bodily exudates temporary stored in the acquisitionlayer 52 of the topsheet/acquisition layer laminate 245 will not readilybe drawn towards and underneath the gasketing cuffs 32 by capillaryforces. Leakage can thus be reduced by having the width of theacquisition layer 52 in a direction parallel to the transversal axis 90less that the width of the topsheet 24 in the topsheet/acquisition layerlaminate 245 in a direction parallel to the transversal axis 90.

In order to help reducing leakage and rewet, the width of theacquisition layer 52 in a direction parallel to the transversal axis 90of the topsheet/acquisition layer laminate 245 may not be more than 40%wider than the width of the distribution layer 54 and/or more than 20%wider than the width of the absorbent core 28 in a direction parallel tothe transversal axis 90. In that case, the liquid bodily exudates maynot accumulate at or adjacent to the transversal edges of theacquisition layer 52. Wicking of the liquid bodily exudates underneaththe gasketing cuffs 32 is prevented. Indeed, when the acquisition layer52 of the tospheet/acquisition layer laminate 245 is no more than 20%wider than the width of the absorbent core 28, the liquid bodilyexudates can readily be transported into the absorbent core 28, whichcan efficiently drain the fluid from the acquisition layer 52 into theabsorbent core 28. Wicking of the liquid bodily exudates form theacquisition layer 52 underneath the gasketing cuffs 32 is prevented.

The acquisition layer 52 can receive the liquid bodily exudates thatpass through the topsheet 24 and can distribute them to underlyingabsorbent layers. In such a case, the topsheet 24 in thetopsheet/acquisition layer laminate 245 may be less hydrophilic than theacquisition layer 52. The topsheet 24 of the topsheet/acquisition layerlaminate 245 can be readily dewatered.

In order to enhance dewatering of the topsheet 24 of thetopsheet/acquisition layer laminate 245, the pore size of theacquisition layer 52 may be reduced. For this, the acquisition layer 52may made of fibers with relatively small denier. The acquisition layer52 may also have an increased density.

The process may comprise the step of joining the portion of thebacksheet web 2555 to the portion of the topsheet web 240 at or adjacentto the transversal edges of the first surface of thetopsheet/acquisition layer laminate web 2450 in the cross direction. Thetransversal edges of the first surface of the topsheet/acquisition layerlaminate web 2450 do not comprise any acquisition layer 52. When theportion of the backsheet web 2555 is joined to the portion of thetopsheet web 240 of the topsheet/acquisition layer laminate web 2450,the acquisition layer 52 is then enveloped between the topsheet web 240and the backsheet web 2555.

The process may comprise the step of cutting into individual absorbentarticles comprising a backsheet 25, a topsheet 24 and an acquisitionlayer 52, characterized in that the topsheet 24 and acquisition layer 52are joined to form a topsheet/acquisition layer laminate 245.

The topsheet/acquisition layer laminate web 2450 may be produced at aparticular location in the process setup. Hence, thetopsheet/acquisition layer laminate web 2450 might be not available tocarry the dry-laid fibrous structure of the distribution layer 54 at thedesired location of the process.

A process of making an absorbent article comprises the step of providinga liquid permeable topsheet web 240 extending substantially continuouslyin a machine direction, the topsheet web 240 having a first and secondsurface, a liquid impermeable backsheet web 2555 extending substantiallycontinuously in the machine direction, an acquisition layer 52 having afirst and second surface, a dry-laid fibrous structure and a carrierlayer web 170 having a first and second surface (171, 172), as shown inFIGS. 9 and 10. The topsheet web 240 and the acquisition layer 52comprise fibers.

The topsheet web 240 and acquisition layer 52 are aligned in a face toface relationship with the acquisition layer 52 such that the secondsurface of the topsheet web 240 is in contact with the first surface ofthe acquisition layer 52. The topsheet web 240 and the acquisition layer52 are simultaneously mechanically deformed and combined together toprovide a topsheet/acquisition layer laminate web 2450 havingthree-dimensional protrusions 250.

The three-dimensional protrusions 250 are formed from the fibers of thetopsheet web 240 and the acquisition layer 52. A majority of thethree-dimensional protrusions 250 each comprises a base 256 forming anopening, an opposed distal portion 257, and one or more side walls 255between the base 256 and the distal portion 257 of the majority of thethree-dimensional protrusion 250. The base 256, distal portion 257 andone or more side walls 255 are formed by fibers such that the majorityof the three-dimensional protrusions 250 has only an opening at the base256. At least 50% or at least 80% of the three-dimensional protrusions250 of the topsheet/acquisition layer laminate 245 may only haveopenings at the base 256. The majority of the three-dimensionalprotrusions 250 may be obtained by the mechanical process described indetail below.

The topsheet/acquisition layer laminate web 2450 has a first surfacecomprising the second surface of the acquisition layer 52.

The fibers 540 of the dry-laid fibrous structure are deposited on thefirst surface 171 of the carrier layer web 170 as shown in FIGS. 9 and10. A portion of the backsheet web 2555 is joined to a portion of thetopsheet web 240 of the topsheet/acquisition layer laminate 2450 suchthat the second surface 172 of the carrier layer web 170 is facing thetopsheet/acquisition layer laminate web 2450 or the backsheet web 2555.

Hence, the carrier layer web 170 can carry out the material of thedistribution layer 54 wherever the topsheet/acquisition layer laminateweb 2450 is produced and provided in the process.

According to the method used for making the three-dimensional structureof the topsheet/acquisition layer laminate web 2450, when the topsheetweb 240 and acquisition layer 52 are mechanically deformed together,holes might unintentionally occur. When the distribution layer 54comprises the dry-laid fibrous structure, the fibers 540 of the dry-laidfibrous structure may pass through the unintentional holes formed at theresulting topsheet/acquisition layer laminate 245 and contactundesirably the skin of the wearer. It may be desirable to prevent thatthe fibers 540 of the dry-laid fibrous structure can pass through theunintentional holes of the resulting topsheet/acquisition layer laminate245.

The carrier layer web 170 may be disposed between thetopsheet/acquisition layer laminate web 2450 and the dry-laid fibrousstructure, as shown in FIG. 9. In the absorbent article 20, the carrierlayer 17 may act as a barrier layer to impede the fibers 540 of thedry-laid fibrous structure from passing through the holes of thetopsheet/acquisition layer laminate 245 unintentionally formed by thethree-dimensional mechanical deformation of the topsheet 24 with theacquisition layer 52, as shown in FIGS. 11 and 12(A-B). Also, thecarrier layer 17 may help the transfer of the liquid bodily exudatesfrom the topsheet/acquisition layer laminate 245 to the dry-laid fibrousstructure.

The first surface 171 of the carrier layer 17 in the absorbent article20 may be attached at or adjacent to its longitudinal edges to theabsorbent core 28. Hence, when the carrier layer 17 is disposed betweenthe topsheet/acquisition layer laminate 245 and the dry-laid fibrousstructure, and the first surface 171 of the carrier layer 17 is attachedto the absorbent core 28, the fibers 540 of the dry-laid fibrousstructure may be not able to escape between the carrier layer 17 and theabsorbent core 28, as exemplified in FIG. 12B. The attachment of thecarrier layer 17 to the longitudinal edges of the absorbent core 28 mayinclude a uniform continuous layer of adhesive 173, a discontinuouspatterned application of adhesive or an array of separate lines,spirals, or spots of adhesive.

Alternatively, the carrier layer web 170 may be disposed between thedry-laid fibrous structure and the absorbent core 28, as shown in FIG.10. Hence, the carrier layer 17 in the absorbent article 20 may help todistribute and transfer of the liquid bodily exudates from thedistribution layer 54 to the absorbent core 28, as shown in FIGS. 13 and14, which enables more efficient use of the absorbent core 28.

The carrier layer 17 may be attached at or adjacent to its longitudinaledges to the first surface of the topsheet/acquisition layer laminate245. Hence, when the carrier layer 17 is disposed between the dry-laidfibrous structure and the absorbent core 28, and the carrier layer 17 isattached to the first surface of the topsheet/acquisition layer laminate245, the fibers 540 of the dry-laid fibrous structure may be not able toescape between the topsheet/acquisition layer laminate 245 and thecarrier layer 17. The attachment of the carrier layer 17 to thelongitudinal edges to the first surface of the topsheet/acquisitionlayer laminate 245 may include a uniform continuous layer of adhesive, adiscontinuous patterned application of adhesive or an array of separatelines, spirals, or spots of adhesive.

The process may comprise the step of cutting into individual absorbentarticles 20 comprising a backsheet 25, a carrier layer 17, a topsheet 24and an acquisition layer 52 characterized in that the topsheet 24 andacquisition layer 52 are joined to form a topsheet/acquisition layerlaminate 245.

The acquisition layer 52 of the topsheet/acquisition layer laminate web2450 may be provided continuously in the machine direction. A length ofthe acquisition layer 52 of the topsheet/acquisition layer laminate 245in a direction parallel to the longitudinal axis 80 may be equal of thelength of the topsheet 24 in a direction parallel to the longitudinalaxis 80 of the absorbent article 20.

Alternatively, the acquisition layer 52 of the topsheet/acquisitionlayer laminate web 2450 may be provided intermittently in the machinedirection. The length of the acquisition layer 52 of thetopsheet/acquisition layer laminate 245 in a direction parallel to thelongitudinal axis 80 may be less than the length of the topsheet 24 in adirection parallel to the longitudinal axis 80 of the absorbent article20, as shown in FIG. 4. When the length of the acquisition layer 52 inthe topsheet/acquisition layer laminate 245 is less than the length ofthe topsheet 24, the liquid bodily exudates cannot be readily drawntowards the longitudinal edges (10, 12) of the absorbent article 20,which reduces leakage.

The length of the acquisition layer 52 in the topsheet/acquisition layerlaminate 245 may be less than the length of the absorbent core 28 takenalong the longitudinal axis 80 of the absorbent article 20, see forexample FIG. 4.

The acquisition layer 52 of the topsheet/acquisition layer laminate 245may be positioned in the front region 36 and at least partially in thecrotch region 37 of the absorbent article 20, as shown in FIG. 15. Inthat case, positioning the acquisition layer 52 of thetopsheet/acquisition layer laminate 245 in the front region 36 of theabsorbent article 20 helps for acquiring and distributing the liquidbodily exudates such as urine, around the pee point of the wearer.

The acquisition layer 52 of the topsheet/acquisition layer laminate 245may be positioned in the back region 38 and at least partially in thecrotch region 37 of the absorbent article 20, as shown in FIG. 16.Positioning the acquisition layer 52 of the topsheet/acquisition layerlaminate 245 in the back region 38 of the absorbent article 20 helps atacquiring the feces of the wearer, especially when the feces have a lowviscosity.

The majority of the three-dimensional protrusions 250 of thetopsheet/acquisition layer laminate 245 may protrude towards thebacksheet 25 or towards the body of the wearer when the absorbentarticle is in use.

The topsheet/acquisition layer laminate 245 may be notionally dividedinto a first and second area. The first area may comprisethree-dimensional protrusions 250 which protrude towards the backsheet25. The second area may comprise three-dimensional protrusions 250 whichprotrude towards the body of the wearer when the absorbent article is inuse.

For instance, the first area may be located in the front region 36 andat least partially in the crotch region 37 of the absorbent article 20.

Having the first area where the three-dimensional protrusions 250 of thetopsheet/acquisition layer laminate 245 protrude towards the backsheet25 can help acquiring and absorbing the liquid bodily exudates to theabsorbent core 28. Having the second area where the three-dimensionalprotrusions 250 of the topsheet/acquisition layer laminate 245 protrudetowards the body of the wearer when the absorbent article is in use canimprove cleaning the body from the exudates. Hence, a combination of thefirst and second area can allow the absorbent article 20 to betterperform.

The topsheet 24 of the topsheet/acquisition layer laminate 245 may becoated with a lotion composition. The lotion composition may be locatedin the areas of the topsheet 24 which are between the three-dimensionalprotrusions 250 of the topsheet/acquisition layer laminate 245.

Typical lotion compositions used in diapers are disclosed in U.S. Pat.No. 6,426,444 B2. The resulting lotion composition may be applied to thetopsheet/acquisition layer laminate by spraying, printing (e.g.,flexographic printing), coating (e.g., contact slot coating, gravurecoating), extrusion, microencapsulation or combinations of theseapplication techniques.

The majority of the three-dimensional protrusions 250 may be disposed inany suitable arrangement across the plane of the topsheet/acquisitionlayer laminate 245. Suitable arrangements include, but are not limitedto: staggered arrangements, and zones. In some cases, thetopsheet/acquisition layer laminate 245 may comprise boththree-dimensional protrusions 250 and other features known in the artsuch as embossments and apertures. The three-dimensional protrusions 250and other features may be in separate zones, be intermixed, or overlap.Intermixed arrangements can be created in any suitable manner. In somecases, intermixed arrangements can be created by using the techniquesdescribed in U.S. Patent Publication No. US 2012/0064298 A1, Orr, et al.In other cases, overlapping arrangements can be created by forming thethree-dimensional protrusions 250 and then subsequently passing thetopsheet/acquisition layer laminate web 2450 between a forming memberhaving male forming elements thereon and a compliant surface, andapplying pressure to the web with the forming member and compliantsurface. These techniques for producing overlapping arrangements enablethree-dimensional protrusions 250 and other features to be combined sothey are disposed in different locations on the topsheet/acquisitionlayer laminate 245 or they can cause at least some of thethree-dimensional protrusions 250 and at least some of the otherfeatures (apertures, embossments) to be disposed in the same location onthe topsheet/acquisition layer laminate 245.

The Carrier Layer

The carrier layer 17 may be selected from the group consisting ofnonwovens, tissues, or films and combinations thereof.

Examples of a nonwoven web used for the carrier layer 17 may includevarious types of known nonwoven webs such as a spunbonded nonwoven web,a meltblown nonwoven web, and a spunbond-meltblown-spunbond nonwovenweb. These nonwoven webs are made of thermoplastic polymers.

A material for fibers composing the nonwoven web used for the carrierlayer 17 may include various types of known fibers such as polyethylene,polypropylene, polyester, and acryl, conjugate fibers such aspolyethylene/polypropylene, polyethylene/polyethylene terephthalate, andpolypropylene/polyethylene terephthalate, i.e., fibers formed ofcore-in-sheath fibers and side-by-side fibers. The fibers may be usedalone or in combination. Further, the carrier layer 17 may have amonolayer structure or a multilayer structure.

The carrier layer 17 may comprise a tissue made of wet-laid fiberscomprising cellulose fibers having a Wet burst Strength from 50 to 500 gaccording to the Wet Burst Strength Test Method and combinationsthereof.

The carrier layer 17 may be treated with a surfactant to render thecarrier layer 17 hydrophilic. The carrier layer 17 may be made of onematerial of the group as set out above, which has been chemicallymodified to render it hydrophilic. The hydrophilic carrier layer 17 maythus improve the transfer of the liquid bodily exudates from thedistribution layer 54 to the absorbent core 28 of the absorbent article20.

The carrier layer 17 may have a basis weight of at least 5 gsm to 60 gsmor at least 5 gsm to 20 gsm or at least 5 to 15 gsm.

The carrier layer 17 may be wider and longer than the distribution layer54. The carrier layer can help preventing the fibers 540 of the dry-laidfibrous structure getting to the skin of the wearer when thedistribution layer 54 comprises the dry-laid fibrous structure and ifthe topsheet/acquisition layer laminate 245 comprises some holes.

The carrier layer 17 may be colored. The process may comprise the stepof providing the carrier layer web 170 which is colored. Color may beimparted to the carrier layer 17 by color pigmentation. The term “colorpigmentation” encompasses any pigments suitable for imparting anon-white color to the carrier layer 17. This term therefore does notinclude “white” pigments such as TiO₂ which are typically added to thelayers of conventional absorbent articles to impart them with a whiteappearance. Pigments are usually dispersed in vehicles or substrates forapplication, as for instance in inks, paints, plastics or otherpolymeric materials.

The pigments may for example be introduced in a polypropylenemasterbatch. A masterbatch comprises a high concentration of pigmentand/or additives which are dispersed in a carrier medium which can thenbe used to pigment or modify the virgin polymer material into apigmented bicomponent nonwoven. An example of suitable coloredmasterbatch material that can be introduced is Pantone color 270 Sanylenviolet PP 42000634 ex Clariant, which is a PP resin with a highconcentration of violet pigment. Typically, the amount of pigmentsintroduced by weight of the carrier layer 17 may be of from 0.3%-2.5%.

Alternatively, color may be imparted to the carrier layer 17 by way ofimpregnation of a colorant into the substrate. Colorants such as dyes,pigments, or combinations may be impregnated in the formation ofsubstrates such as polymers, resins, or nonwovens. For example, thecolorant may be added to molten batch of polymer during film, fiber, orfilament formation.

When viewing the absorbent article 20 from the topsheet 24, the coloredcarrier layer 17 may provide to a caregiver an enhanced impression ofdepth to support to the impression given by the three-dimensionalprotrusions 250 as such, as long as the colored carrier layer 17 arevisible from the topsheet 24. Hence, a colored carrier layer 17 cansupport the caregiver's perception that the absorbent article 20 is wellable to absorb the liquid bodily exudates.

The topsheet 24 and/or acquisition layer 52 of the topsheet/acquisitionlayer laminate 245 may be colored, for the same reasons.

The carrier layer 17 may be porous, may have a relatively highpermeability and have a relatively high level of saturation when exposedto fluid at suction pressures such as 20 cm water. The relatively highlevel of saturation of the carrier layer 17 can be defined as the ratiobetween the volume of liquid bodily exudates in the pores of the carrierlayer 17 and the total void volume of the carrier layer 17. The carrierlayer 17 can help providing connectivity between the acquisition layer52 of the topsheet/acquisition layer laminate 245 and the distributionlayer 54.

Also, the carrier layer 17 may comprise some relative small sized holessuch that the fibers 540 of the dry-laid fibrous structure of thedistribution layer 54 may partially pass through the holes of thecarrier layer. Hence, the fibers 540 of the dry-laid fibrous structurecan entangle and contact the acquisition layer 52 of thetopsheet/acquisition layer laminate 245. The carrier layer 17 maycomprise holes having a size from 0.02 mm to 10 mm.

The Mechanical Deformations and the Resulted Three-DimensionalProtrusions

The step of the process 100 related to mechanically deforming andcombining the topsheet 24 with the acquisition layer 52 may comprise thefollowing step of providing a first and second forming member (211, 212)having a machine direction and a cross direction orientation, as shownin FIGS. 17A, 17B and 17C. The first and second forming member (211,212) may be drum-shaped, generally cylindrical or plate-shaped.

The first forming member 211 of the apparatus 200 may have a surfacecomprising a plurality of discrete, spaced apart male forming elements213 having a base that is joined to the first forming member 211, a topthat is spaced away from the base, and sides that extend between thebase and the top of the male forming elements 213. The male formingelements 213 may have a plan view periphery, and a height.

The top on the male forming elements 213 may have a rounded diamondshape, see for example FIG. 17A, with vertical sidewalls and a radiusedor rounded edge at the transition between the top and the sidewalls ofthe male forming element 213.

The second forming member 212 may have a surface comprising a pluralityof recesses 214 in the second forming member 212. The recesses 214 maybe aligned and configured to receive the respective male formingelements 213 therein. Hence, each recess 214 of the second formingmember 212 may be sufficiently large to be able to receive eachrespective male forming element 213 of the first forming member 211. Therecesses 214 may have a similar shape as the male forming elements 213.The depth of the recesses 214 may be greater than the height of the maleforming elements 213.

The first and second forming member (211, 212) may be further defined bya depth of engagement (DOE) which is a measure of the level ofintermeshing of the first and second forming member (211, 212), as shownin FIG. 17C. The depth of engagement (DOE) may be measured from the tipof the male forming elements 213 to the outermost portion of the surfaceof the second forming member 212 which portions are not within a recess214. The depth of engagement (DOE) may range from 1.5 mm to 5.0 mm orfrom 2.5 mm to 5.0 mm or from 3.0 mm to 4.0 mm.

The first and second forming member (211, 212) may be defined by aclearance between the first and second forming member (211, 212) asshown in FIG. 17C. The clearance is the distance between the side wallof the male forming element 213 and the side wall of the recess 214. Theclearance may range from 0.1 mm to 2 mm or from 0.1 mm to 1.5 mm from0.1 mm to 1 mm.

The topsheet 24 and the acquisition layer 52 may be engaged togetherbetween the first and second forming members (211, 212) and bemechanically deformed and combined together to form thetopsheet/acquisition layer laminate 245. The topsheet/acquisition layerlaminate 245 comprises thus deformations forming three-dimensionalprotrusions 250.

The topsheet/acquisition layer laminate 245 may be notionally dividedinto a first and second area. The first and/or second area of thetopsheet/acquisition layer laminate 245 may comprise the majority of thethree-dimensional protrusions 250 having different shapes.

Viewed from a cross-sectional view, i.e. in a Z-direction, the majorityof the three-dimensional protrusions 250 may have any suitable shapeswhich include, but are not limited to: bulbous-shaped, conical-shapedand mushroom shaped.

Viewed from above, the majority of the three-dimensional protrusions 250may have any suitable shapes which include, but are not limited to:circular, diamond-shaped, round diamond-shaped, U.S. football-shaped,oval-shaped, clover-shaped, triangular-shaped, tear-drop shaped andelliptical-shaped protrusions. The majority of the three-dimensionalprotrusions 250 may be non-circular.

The majority of the three-dimensional protrusions 250 may form, inconjunction, one or more graphics. Having graphics can support thecaregiver's perception that the absorbent article is well able to absorbthe liquid bodily exudates.

Also, the majority of the three-dimensional protrusions 250 may form, inconjunction, one or more graphics such as a logo, e.g. the Pampers Heartlogo.

The majority of the three-dimensional protrusions 250 may have similarplan view dimensions in all directions, or the majority of thethree-dimensional protrusions 250 may be longer in one dimension thananother. The majority of the three-dimensional protrusions 250 may havedifferent length and width dimensions. The majority of thethree-dimensional protrusions 250 may, thus, have a ratio of length towidth. The ratio of length to width can range from 10:1 to 1:10.

The topsheet/acquisition layer laminate 245 may comprise a plurality ofthree-dimensional protrusions 250 which may extend towards thedistribution layer 54 (see also FIG. 2) or towards the carrier layer 17(see FIGS. 11, 12). When the majority of the three-dimensionalprotrusions 250 extend towards the distribution layer 54, the area ofcontact between the acquisition layer 52 of the topsheet/acquisitionlayer laminate 245 and the underneath distribution layer 54 is improved.The distribution layer 54 will follow the shape of the majority of thethree-dimensional protrusions 250. Hence, the transfer of the liquidbodily exudates from the topsheet/acquisition layer laminate 245 to thedistribution layer 54 can be increased.

FIG. 18A-FIG. 18F shows different alternatives of three-dimensionalprotrusions 250. A bulbous-shaped protrusion may be one type ofthree-dimensional protrusions 250 which may be obtained by the processstep described above using the apparatus 200. The topsheet/acquisitionlayer laminate 245 may comprise the majority of the of three-dimensionalprotrusions 250 protruding towards the backsheet 25.

As shown in FIG. 18A, the three-dimensional protrusion 250 is formedfrom the fibers of the topsheet 24 and the acquisition layer 52. Thethree-dimensional protrusion 250 is defined by a base 256 forming anopening and having a protrusion base width, an opposed enlarged distalportion 257 that extends to a distal end 259 and one or more side walls255 between the base 256 and the distal portion 257. The base 256,distal portion 257 and the one or more side walls 255 are formed byfibers such that the three-dimensional protrusion 250 has only anopening at the base 256, as shown in FIG. 18A. The side wall 255 may besubstantially continuous. For instance, the side wall 255 may bespherical or conical. The three-dimensional protrusion 250 may comprisemore than one side wall 255, e.g. in a pyramidal-shaped protrusion. Thefibers may substantially or completely surround the one or more sidewalls 255 of the three-dimensional protrusions 250.

As shown in FIG. 18B, a three-dimensional protrusion 250 comprising aninner and outer three-dimensional protrusion 251A and 251B may be madefrom engaging the topsheet web 240 with the acquisition layer 52 betweenthe first and second forming member (211, 212) such as the innerthree-dimensional protrusion 251A from the topsheet 24 and the outerthree-dimensional protrusion 251B from the acquisition layer 52 coincidewith and fit together. Hence, as shown in FIG. 18B, the innerthree-dimensional protrusion 251A of the topsheet 24 and the outerthree-dimensional protrusion 251B of the acquisition layer 52 are nestedtogether.

The inner three-dimensional protrusion 251A may comprise a plurality offibers 254A which constitutes the topsheet 24. The outerthree-dimensional protrusion 251B in which the inner three-dimensionalprotrusion 251A may be nested, may comprise a plurality of fibers 254Bwhich constitutes the acquisition layer 52. The plurality of fiber(254A, 254B) composing the three-dimensional protrusion 250 may surroundthe side walls 255 of the three-dimensional protrusions 250.

The topsheet 24 and the acquisition layer 52 may be both extensible. Thefibers composing the topsheet 24 and acquisition layer 52 may elongateand/or may be mobile, such that the topsheet 24 and acquisition layer 52are able to stretch to be nested together.

Generally, the extensibility of the materials composing the topsheet 24and acquisition layer 52 can be selected according to the desired sizesof the three-dimensional protrusions 250. If relatively largethree-dimensional protrusions 250 are desired, materials with arelatively higher extensibility will be chosen.

For instance, the topsheet 24 or acquisition layer 52 may be capable ofundergoing an apparent elongation of equal to or greater than at least100% or 110% or 120% or 130% up to 200% in the machine and/orcross-machine directions at or before reaching the breaking forceaccording to the Test Method as set out in the Definition part.

In some cases, it might be desired to have three-dimensional protrusions250 which are larger either in the machine or cross-machine direction.For this, the materials composing the topsheet 24 and acquisition layer52 can be thus more extensible in either machine versus cross-machinedirection or vice versa.

The majority of the three-dimensional protrusions 250 may comprise avoid area 253 which is the portion of the three-dimensional protrusion251A which does not comprise any fibers or very little fibers. Themajority of the three-dimensional protrusions 250 may be defined by aprotrusion base width WB₁ of the base 256 forming an opening which ismeasured from two side walls of the inner portion 251A at the base 256.The majority of the three-dimensional protrusions 250 may be defined bya width WD₂ of the void area 253 which is the maximum interior widthmeasured between two side walls of the inner three-dimensionalprotrusion 251A or which is the maximum diameter of the side wall whenthe distal portion has a substantially circular shape. The maximuminterior width WD₂ of the void area 253 at the distal portion may begreater than the protrusion base width WB₁ of the base 256 of themajority of the three-dimensional protrusions 250. This is the case forsome types of three-dimensional shapes, such as bulbous shapes asexemplified in FIG. 18B but nor for conical shape. The protrusion basewidth protrusion base WB₁ of the base 256 of the three-dimensionalprotrusion 250 may range from 1.5 mm to 15 mm or from 1.5 mm to 10 mm orfrom 1.5 mm to 5 mm or from 1.5 mm to 3 mm. Measurements of thedimensions of the protrusion base width WB₁ of the base 256 and thewidth WD₂ of the distal portion 257 can be made on a photomicrograph.

When the size of the protrusion base width WB₁ of the base 256 isspecified herein, it will be appreciated that if the openings are not ofuniform width in a particular direction, the protrusion base width, WB₁,is measured at the widest portion. Measurements of the width protrusionbase WB₁ of the base 256 or the maximum interior width WD₂ of the voidarea 253 at the distal portion 257 can be made on a photomicrograph at20× magnification.

As the plurality of fiber (254A, 254B) composing the majority of thethree-dimensional protrusions 250 may be present in the one or more sidewalls 255 of the majority of the three-dimensional protrusions 250, themajority of the three-dimensional protrusions 250 may not collapse onone side and close off the opening at the base 256 when compressiveforces are applied on the topsheet/acquisition layer laminate 245. Theopening at the base 256 may be maintained and may create a ring ofincreased opacity around the opening at the base 256 when thethree-dimensional protrusions 250 has been compressed. Hence, themajority of the three-dimensional protrusion 250 can be preserved andremain visible to the consumer when viewing the absorbent article 20from the topsheet 24. The majority of the three-dimensional protrusions250 can be preserved after being subjected to any inherent compressiveforces due to the process or the step of compressing the absorbentarticles comprising the topsheet/acquisition layer laminate 245 prior tobe filled in a packaging.

In other words, the majority of the three-dimensional protrusions 250may have a degree of dimensional stability in the X-Y plane when aZ-direction force is applied to the majority of the three-dimensionalprotrusions 250. It is not necessary that the collapsed configuration ofthe majority of the three-dimensional protrusions 250 be symmetrical,only that the collapsed configuration prevent the majority of thethree-dimensional protrusions 250 from flopping over or pushing backinto the original plane of the topsheet/acquisition layer laminate 245.Without wishing to be bound to any particular theory, the wide base 256and large cap 52 (greater than the protrusion base width of the baseopening 256), combined with the lack of a pivot point, causes thethree-dimensional protrusions 250 to collapse in a controlled manner(the large distal portion 257 prevents the three-dimensional protrusion250 from flopping over and pushing back into the original plane of thetopsheet/acquisition layer laminate 245). Thus, the majority of thethree-dimensional protrusions 250 are free of a hinge structure thatwould otherwise permit them to fold to the side when compressed.

It may be desirable for at least one of the three-dimensionalprotrusions 250 in the topsheet/acquisition layer laminate 245 tocollapse in a controlled manner described below under the 7 kPa loadwhen tested in accordance with the Accelerated Compression Method in theTest Methods section below.

Alternatively, at least some, or in other cases, a majority of thethree-dimensional protrusions 250 may collapse in the controlled mannerdescribed herein.

Alternatively, substantially all of the three-dimensional protrusions250 may collapse in the controlled manner described herein. The abilityof the three-dimensional protrusions 250 to collapse may also bemeasured under a load of 35 kPa. The 7 kPa and 35 kPa loads may simulatemanufacturing and high compression packaging conditions. Wear conditionscan range from 2 kPa or less up to 7 kPa.

Generally, the majority of the three-dimensional protrusions 250 may beconfigured to collapse in a controlled manner such that each base 256forming an opening remains open, and the protrusion base width of eachbase 256 forming an opening is greater than 0.5 mm after compression.

In the area of the three-dimensional protrusions 250, the topsheet 24and/or acquisition layer 52 may comprise one or more interruptions. Theformation of the one or more interruptions may be due to the propertiesof the topsheet 24 and acquisition layer 52. The topsheet 24 may lessextensible with regard to fiber mobility and/or fiber extensibility thanthe acquisition layer 52 or vice versa such that a hole starts to formin the topsheet 24 and/or acquisition layer 52. As shown in FIG. 18C,the acquisition layer 52 may be interrupted in the area of thethree-dimensional protrusion 250 of the topsheet/acquisition layerlaminate 245.

Generally, the acquisition layer 52 may have a lower extensibility thanthe topsheet 24. In such cases, the acquisition layer 52 may start torupture and form an interruption, i.e. the fibers composing theacquisition layer 52 may be less extensible and/or mobile than thefibers composing the topsheet 24.

The three-dimensional protrusion 251A made of the respective othernon-interrupted topsheet interpenetrates the interrupted acquisitionlayer 52. In such case, the interruptions may be formed by locallyrupturing the acquisition layer 52 by the process described in detailabove. The interpenetration may be achieved by pushing the topsheet web240 through the acquisition layer 52. In order to obtain thesethree-dimensional protrusions, the depth of engagement (DOE) of theapparatus 200 may be adequately selected from 2 to 10 mm, or from 3 to 7mm. The interrupted acquisition layer 52 may have any suitableconfiguration in the area of the three-dimensional protrusion 250. Therupture may involve a simple splitting open of the acquisition layer 52such that the interruption in the acquisition layer 52 remains a simpletwo-dimensional hole. It might happen that a portion of the acquisitionlayer 52 in the area of the three-dimensional protrusion 250 may beslightly deflected or urged out-of-place to form flaps 269.

When the respective other non-interrupted topsheet 24 interpenetratesthe interrupted acquisition layer 52, the topsheet 24 can be brought indirect contact with the underlying layer, e.g. the carrier layer 17, thedistribution layer 54 or the absorbent core 28 leading to an efficienttopsheet dewatering, which can improve the dryness of thetopsheet/acquisition layer laminate 245.

Alternatively, as shown in FIG. 18D or 18E, the acquisition layer 52 maybe interrupted in in the area of the three-dimensional protrusion 250 ofthe topsheet/acquisition layer laminate 245. The three-dimensionalprotrusion 251B of the interrupted acquisition layer 52 may comprise aninterruption (258B). The three-dimensional protrusion 251A of thenon-interrupted topsheet 24 may coincide with and fit together with thethree-dimensional protrusion 251B of the interrupted acquisition layer,as shown in FIG. 18D. In other words, the topsheet 24 is not pushedthrough the acquisition layer 52 such that the topsheet 24 does notinterpenetrate through the acquisition layer 52.

Alternatively, the three-dimensional protrusion 251A of thenon-interrupted topsheet 24 may partially fit together with thethree-dimensional protrusion 251B of the interrupted acquisition layer,as shown in FIG. 18E.

Likewise, the topsheet 24 may be interrupted in the area of thethree-dimensional protrusion 250 of the topsheet/acquisition layerlaminate 245.

Generally, the topsheet 24 may have a lower extensibility than theacquisition layer 52. In such cases, the topsheet 24 may start torupture and form an interruption, i.e. the fibers composing the topsheet24 may be less extensible and/or mobile than the fibers composing theacquisition layer 52.

In another alternative, the topsheet 24 and acquisition layer 52 may beinterrupted in the area of the three-dimensional protrusions 250 of thetopsheet/acquisition layer laminate 245 and the three-dimensionalprotrusions of the topsheet 251A coincide with and fit together with thethree-dimensional protrusions 251B of the acquisition layer. Theinterruptions 258A in the topsheet 24 in the area of thethree-dimensional protrusions 250 of the topsheet/acquisition layerlaminate 245 will not coincide with the interruptions 258B in theacquisition layer 52 in the area of the three-dimensional protrusions250 of the topsheet/acquisition layer laminate 245, as shown in FIG.18F. In this case, the interruptions (258A, 258B) in the topsheet 24 andacquisition layer 52 are in different locations in the three-dimensionalprotrusions 250.

The majority of the three-dimensional protrusions 250 may protrudetowards the body of the wearer when the absorbent article 20 is in use(see also FIG. 3). When the majority of the three-dimensionalprotrusions 250 protrude towards the body of the wearer when theabsorbent article 20 is in use, the area of contact between the topsheet24 of the topsheet/acquisition layer laminate 245 and the wearer's skincan be reduced in order to lead to an enhanced dryness feeling andcomfort. Hence, the topsheet/acquisition layer laminate 245 providescushioning to the wearer and an improved sensation of comfort.

FIG. 19A-FIG. 19E shows alternatives how a plurality ofthree-dimensional protrusions 250, e.g. bulbous-shaped protrusions, mayprotrude from the acquisition layer 52 to the topsheet 24 of thetopsheet/acquisition layer laminate 245. In those alternatives, athree-dimensional protrusion 250 may comprise an inner and outerthree-dimensional protrusion 251A and 251B. The inner three-dimensionalprotrusion 251A of the acquisition layer 52 is nested in the outerthree-dimensional protrusion 251B of the topsheet 24. The innerthree-dimensional protrusion 251A may comprise a plurality of loopedfibers 254B of the acquisition layer 52. The outer three-dimensionalprotrusion 251B in which the inner three-dimensional protrusion 251A isnested, may comprise a plurality of looped fibers 254A of the topsheet24.

An area of 10 cm² of the topsheet/acquisition layer laminate 245 maycomprise from 5 to 100 three-dimensional protrusions 250 from 10 to 50three-dimensional protrusions 250 or from 20 to 40 three-dimensionalprotrusions 250.

Fiber Concentration

The topsheet web 240 may comprise a generally planar first region of thetopsheet web 240. The acquisition layer 52 may comprise a generallyplanar first region of the acquisition layer 52. The three-dimensionalprotrusions of the respective topsheet web 240 and the acquisition layer52 may comprise a plurality of discrete integral second regions. Theterm “generally planar” is not meant to imply any particular flatness,smoothness, or dimensionality. Thus, the first region of the topsheetweb 240 can include other features that provide the first region of thetopsheet web 240 with a topography. The first region of the acquisitionlayer 52 can include other features that provide the first region of theacquisition layer 52 with a topography. Such other features can include,but are not limited to small protrusions, raised network regions aroundthe base 256 forming an opening, and other types of features. Thus, thefirst region of the topsheet web 240 and/or the first region of theacquisition layer 52 can be generally planar when considered relative tothe respective second regions. The first region of the topsheet web 240and/or the first region of the acquisition layer 52 can have anysuitable plan view configuration. In some cases, the first region of thetopsheet web 240 and/or the first region of the acquisition layer 52 canbe in the form of a continuous inter-connected network which comprisesportions that surround each of the three-dimensional protrusions 250.

The side walls 259 and the area around the base 256 of the majority ofthe three-dimensional protrusions 250 may have a visibly significantlylower concentration of fibers per given area (which may be evidence of alower basis weight or lower opacity) than the portions of the topsheetweb 240 and/or the acquisition layer 52 in the unformed first region ofthe respective topsheet web 240 and the acquisition layer 52. Themajority of the three-dimensional protrusions 250 may also have thinnedfibers in the side walls 259. Thus, the fibers may have a firstcross-sectional area when they are in the undeformed topsheet web 240and the acquisition layer 52, and a second cross-sectional area in theside walls 259 of the majority of the three-dimensional protrusions 250of the topsheet/acquisition layer laminate 245, wherein the firstcross-sectional area is greater than the second cross-sectional area.The side walls 259 may also comprise some broken fibers as well. Theside walls 259 may comprise greater than or equal to about 30%,alternatively greater than or equal to about 50% broken fibers.

As used herein, the term “fiber concentration” has a similar meaning asbasis weight, but fiber concentration refers to the number offibers/given area, rather than g/area as in basis weight.

The topsheet/acquisition layer laminate web 2450 may comprise themajority of the three-dimensional protrusions 250 which are orientedwith the base 256 facing upward in which the concentration of fibers atthe distal end 259 of each respective topsheet web 240 and theacquisition layer 52 differs between the topsheet web 240 and theacquisition layer 52.

The concentration of fibers in the first region of the acquisition layer52 and in the distal ends 259 of the majority of the three dimensionalprotrusions 250 may be greater than the concentration of fibers in theside walls 255 of the majority of the three dimensional protrusions 250in the acquisition layer 52

The concentration of fibers in the first region of the topsheet web 240and in the distal ends 259 of the majority of the three dimensionalprotrusions 250 may be greater than the concentration of fibers in theside walls 255 of the majority of the three dimensional protrusions 250in the topsheet web 240.

Alternatively, the concentration of fibers in the first region of theacquisition layer 52 may be greater than the concentration of fibers inthe side walls 255 of the majority of the three-dimensional protrusions250 in the acquisition layer 52, and the concentration of fibers in theside walls 255 of the majority of the three-dimensional protrusions 250in the acquisition layer 52 may be greater than the concentration offibers forming the distal ends 259 of the majority of thethree-dimensional protrusions 250 in the acquisition layer 52.

The concentration of fibers in the first region of the acquisition layer52 may be greater than the concentration of fibers in the distal ends259 of the majority of the three dimensional protrusions 250 in theacquisition layer 52, and the concentration of fibers in the firstregion of the topsheet web 240 and the distal ends 259 of the majorityof the three dimensional protrusions 250 may be greater than theconcentration of fibers in the side walls 255 of the majority of thethree dimensional protrusions 250 in the topsheet web 240.

A portion of the fibers that form the first region fibers in theacquisition layer 52 and/or the topsheet web 240 may comprise thermalpoint bonds, and the portion of the fibers in the acquisition layer 52and/or the topsheet web 240 forming the side walls 255 and distal ends259 of the majority of the three-dimensional protrusions 250 may besubstantially free of thermal point bonds. In at least some of thethree-dimensional protrusions, at least some of the fibers in theacquisition layer 52 and/or the topsheet web 240 may form a nest orcircle around the perimeter of the three-dimensional protrusion 250 atthe transition between the side wall 255 and the base 256 of thethree-dimensional protrusion 250.

In some cases, the topsheet web 240 or the acquisition layer 52 may havea plurality of bonds (such as thermal point bonds) therein to hold thefibers together. Any such bonds are typically present in the precursormaterials from which the respective topsheet web 240 or the acquisitionlayer 52 are formed.

Forming three-dimensional protrusions 250 in the topsheet/acquisitionlayer laminate web 2450 may also affect the bonds (thermal point bonds)within the topsheet web 240 and/or the acquisition layer 52.

The bonds within the distal end 259 of the three-dimensional protrusions250 may remain intact (not be disrupted) by the mechanical deformationprocess that formed the three-dimensional protrusions 250. In the sidewalls 255 of the three-dimensional protrusions 250, however, the bondsoriginally present in the precursor topsheet web 240 and/or theacquisition layer 52 may be disrupted. When it is said that the bondsmay be disrupted, this can take several forms. The bonds can be brokenand leave remnants of a bond. In other cases, such as where theprecursor materials of the respective topsheet web 240 or theacquisition layer 52 is underbonded, the fibers can disentangle from alightly formed bond site (similar to untying a bow), and the bond sitewill essentially disappear. In some cases, after the mechanicaldeformation process, the side walls 255 of the majority of thethree-dimensional protrusions 250 may be substantially free (orcompletely free) of thermal point bonds.

The bonds within the first region of the topsheet web 240 and the distalend 259 of the three-dimensional protrusions 250 may remain intact. Inthe side walls 255 of the three-dimensional protrusions 250, however,the bonds originally present in the precursor topsheet web 240 may bedisrupted such that the side walls 255 are substantially free of thermalpoint bonds. Such a topsheet web 240 could be combined with anacquisition layer 52 in which the concentration of fibers within thetopsheet web 240 in the first region and the distal end 259 of thethree-dimensional protrusions 250 is also greater than the concentrationof fibers in the side walls 255 of the three-dimensional protrusions250.

The acquisition layer 52 may have thermal point bonds within the firstregion of the acquisition layer 52 and the distal end 259 of thethree-dimensional protrusions 250 that remain intact. In the side walls255 of the three-dimensional protrusions 250, however, the bondsoriginally present in the precursor acquisition layer 52 comprising theacquisition layer 52 may be disrupted such that the side walls 255 ofthe acquisition layer 52 are substantially free of thermal point bonds.In other cases, the thermal point bonds in the acquisition layer 52 atthe distal end 259 of the three-dimensional protrusions 250 may also bedisrupted so that the distal end 259 of at least some of thethree-dimensional protrusions 250 are substantially or completely freeof thermal point bonds.

Indicia

The topsheet web 240, the acquisition layer 52, and/or the carrier layerweb 170 may comprise one or more indicia. In other instances, more thanone of these layers or webs may comprise an indicia.

The term “indicia”, as used herein, may comprise one or more inks withpigments, adhesives with pigments, words, designs, trademarks, graphics,patterns, and/or pigmented areas, for example. The term “indicia” doesnot include a fully tinted or colored layer. The indicia may typicallybe a different color than: (1) the layer or web that it is printed on,positioned on, or applied to; or (2) a different color than other layersor webs of an absorbent article 20.

The phrase a “different color” means a different shade of the same color(e.g., dark blue and light blue) or may be completely different color(e.g., blue and gray).

The indicia should be at least partially visible from either a wearerfacing surface, a garment facing surface, or both of an absorbentarticle 20, although the indicia may not be printed on, positioned or,on applied to the wearer or garment facing surfaces of the absorbentarticles 20.

The indicia may be printed on, positioned on, or applied tothree-dimensional protrusions areas and non three-dimensionalprotrusions areas, three-dimensional protrusion areas only, or nonthree-dimensional protrusions areas only, for example. Athree-dimensional protrusion area may comprise a portion or all of themajority of the three-dimensional protrusions 250.

The indicia may comprise a light activatable material, a liquidactivatable material, a pH activatable material, a temperatureactivatable material, a menses activatable material, a urine activatablematerial, or BM activatable material, or an otherwise activatablematerial. These activatable materials may typically undergo a chemicalreaction, or other reaction, to change the indicia from one color to adifferent color, from one color to a different shade of the same color,from a color that is not visually distinguishable in an absorbentarticle 20 to a color that is visually distinguishable in an absorbentarticle 20, or from a color that is visually distinguishable in anabsorbent article 20 to a color that is not visually distinguishable inan absorbent article 20.

In an instance, the indicia may grow or shrink or display a graphic/notdisplay a graphic after the indicia undergoes the reaction. In otherinstances, the indicia may be activated by a stress or a strain duringmanufacture or wear.

The indicia may be white or non-white. If the indicia is white in color,at least one layer may be non-white so that the indicia is visible froma wearer and/or garment facing surface of the absorbent articles 20, forexample.

The indicia may comprise embossments, fusion bonds, or other mechanicaldeformations. In other instances the indicia may at least partiallyoverlap embossments, fusion bonds, or other mechanical deformations.

In some instances, the indicia may be formed within either a sheath or acore of bicomponent fibers. For example, a core may be white, while asheath may be blue, or vice versa.

The indicia may be on, positioned on, formed on, formed with, printedon, or applied to all of, or part of, a certain layer or web. Theindicia may also be on, positioned on, formed on, formed with, printedon, or applied to one or more layers or webs, or on all suitable layersor webs of an absorbent article 20. The indicia may be on, positionedon, formed on, formed with, printed on, or applied to either side, orboth sides, of the one or more layers or webs of an absorbent article20. In some instances, suitable layers or webs for indicia placementcomprise one or more of a topsheet web 240 or topsheet 24, a secondarytopsheet, an acquisition layer 52, a distribution layer 54, a carrierlayer web 170 or carrier layer 17, a core wrap 160, a bottom side 16′ ofthe core wrap 160, a top side 16 of the core wrap 160, and/or anadditional layer positioned at least partially intermediate the topsheet24 and the top side 16 of the core wrap 160 (hereafter sometimesreferred to as “materials suitable for indicia placement”).

Either in addition to or separate from the indicia described above, anyone or more of the suitable layers or webs for indicia placement, or aportion thereof, may have a color different than any one or more of theremaining layers or webs for indicia placement, or a portion thereof.The definition of the phrase “different color” above also applies tothis part of the disclosure. In some instances, the indicia may be adifferent color than any one or more of the suitable layers or webs forindicia placement.

Alternatively, an indicia may be on one of the suitable layers or websfor indicia placement while another one of the remaining suitable layersor webs for indicia placement may be a different color than the indicia.One example may be a blue indicia on a white carrier layer web 170 withthe acquisition layer 52 or topsheet web 240 being teal.

In another example, a blue indicia may be on a white carrier layer web170 with the acquisition layer 52 and topsheet web 240 also being white.As such, the blue indicia may be viewable from a wearer-facing surface.

In another example, a blue indicia may be on an acquisition layer 52,wherein the topsheet web 240 and the acquisition layer 52 aresimultaneously mechanically deformed and combined together, preferablynested together to provide a topsheet/acquisition layer laminate web2450 having three-dimensional protrusions 250.

In an instance where the topsheet and the acquisition layer aresimultaneously mechanically deformed and combined together, preferablynested together to provide a topsheet/acquisition layer laminate web2450 having three-dimensional protrusions 250, the indicia may beapplied to the acquisition layer 52 or the topsheet web 240 before orafter such mechanical deformation (or preferably namely nesting).

In an example, two different indicia may be positioned on the same ordifferent layers or webs for indicia placement. The two differentindicia may be different in color, pattern, and/or graphic, for example.If the two different indicia are on different layers or webs for indiciaplacement, the two layers may be the same color or different colors, orhave portions that are the same color or different colors.

In some instances, a visible color of a portion of, or all of, theinterior (wearer-facing surface) of an absorbent article 20 may becoordinated with and/or compliment a visible color of a portion of, orall of, the exterior (garment-facing surface) of the absorbent article20, as described in further detail in U.S. Pat. No. 8,936,584. Theindicia visible from the interior may also be coordinated with and/orcompliment the indicia visible from the exterior of the absorbentarticle 20. In such an instance, the backsheet 25 of the absorbentarticle 20 may comprise an outer cover nonwoven and a backsheet film.The indicia visible from the exterior of the absorbent article 20 may beon the outer cover nonwoven or the backsheet film.

In still other instances, the visible indicia and/or color from theinterior may also be coordinated with or compliment the indicia and/orcolor visible from the exterior of the absorbent article 20.

In addition to that described above, a first portion of one of thesuitable layers or webs for indicia placement may be a first color and asecond portion of the same of the suitable layers or webs for indiciaplacement may be a second color. The first and second colors may be adifferent color. In other instances, a first portion of one of thesuitable layers or webs for indicia placement may be a first color and asecond portion of a different one of the suitable layers or webs forindicia placement may be a second color. The first and second colors maybe a different color.

In an instance, in an absorbent article 20, one of a topsheet 24, anacquisition layer 52, a portion of a core wrap 160, or an additionallayer (e.g., a carrier layer 170) may be a different color than adifferent one of the topsheet 24, the acquisition layer 52, the portionof the core wrap 160, or the additional layer.

In another instance, in an absorbent article 20, one of a portion of atopsheet 24, a portion of an acquisition layer 52, a portion of a corewrap 160, or a portion of an additional layer may be a different colorthan a different one of the portion of the topsheet 24, the portion ofthe acquisition layer 52, the portion of the core wrap 160, or theportion of the additional layer.

In another instance, in an absorbent article 20, a first portion of oneof a topsheet 24, an acquisition layer 52, a portion of a core wrap 160,or an additional layer may be a different color as a second portion ofthe same one of the topsheet 24, the acquisition layer 52, the core wrap160, or the additional layer.

The process of the present disclosure may comprise applying the indiciato or positioning or printing the indicia on the topsheet web 240, theacquisition layer 52, the carrier layer web 170, a portion of the corewrap 160, and/or an additional layer positioned at least partiallyintermediate the topsheet web 240 and the backsheet web 2555. Theindicia may be positioned or printed on or applied to either side of thetopsheet web 240, the acquisition layer 52, the carrier layer web 170,the portion of the core wrap 160, and/or the additional layer positionedat least partially intermediate the topsheet web 240 and the backsheetweb 2555. If the indicia is applied to or positioned or printed on thetopsheet web 240 or the acquisition layer 52, this step may be donebefore or after the topsheet web 240 and the acquisition layer 52 aresimultaneously mechanically deformed and combined together to providethe topsheet/acquisition layer laminate web 2450.

In some forms, the indicia may be positioned or printed on or applied toa carrier layer web 170 that comprises pulp fibers. In other forms, theindicia may be positioned or printed on or applied to a garment-facingsurface or a wearer-facing surface of the acquisition layer 52. In someinstances, the materials suitable for indicia placement may be purchasedwith indicia thereon or the indicia may be applied to or printed orpositioned on before or during feeding these materials into an absorbentarticle manufacturing line.

Precursor Materials for the Topsheet and the Acquisition Layer

The topsheet/acquisition layer laminate 245 of the present invention canbe made of any suitable nonwoven materials (“precursor materials”). Insome cases, the topsheet/acquisition layer laminate 245 may also be freeof cellulose materials. The precursor materials for thetopsheet/acquisition layer laminate 245 may have suitable properties inorder to be deformed. The suitable properties of the precursor materialsmay include: apparent elongation of the fibers, fiber mobility, abilityto deform and stretch in the area where the three-dimensionalprotrusions 250 of the topsheet/acquisition layer laminate 245 areformed. Hence, the precursor materials are capable of undergoingmechanical deformation to ensure that the three-dimensional protrusion250 will not tend to recover or return to the prior configuration of aflat topsheet 24 laminated on a flat acquisition layer 52.

Several examples of nonwoven materials suitable for use as a topsheet 24for the topsheet/acquisition layer laminate 245 may include, but are notlimited to: spunbonded nonwovens; carded nonwovens; and nonwovens withrelatively specific properties to be able to be readily deformed.

One suitable nonwoven material as a topsheet 24 for thetopsheet/acquisition layer laminate 245 may be an extensiblepolypropylene/polyethylene spunbonded nonwoven. One suitable nonwovenmaterial as a topsheet 24 for the topsheet/acquisition layer laminate245 may be a spunbonded nonwoven comprising polypropylene andpolyethylene. The fibers may comprise a blend of polypropylene andpolyethylene. Alternatively, the fibers may comprise bicomponent fibers,such as a sheath-core fiber with polyethylene on the sheath andpolypropylene in the core of the fiber.

The topsheet 24 of the topsheet/acquisition layer laminate 245 may havea basis weight from 8 to 40 gsm or from 8 to 30 gsm or from 8 to 20 gsm.

Suitable nonwoven materials for the acquisition layer 52 of thetopsheet/acquisition layer laminate 245 may include, but are not limitedto: spunbonded nonwovens, through-air bonded (“TAB”) carded high loftnonwoven materials, spunlace nonwovens, hydroentangled nonwovens, andresin bonded carded nonwoven materials. Spunbonded PET may be denserthan carded nonwovens, providing more uniformity and opacity. Since PETfibers are not very extensible, the nonwoven can be bonded such that atleast some of the fibers can be separated easily from the bond sites toallow the fibers to pull out of the bond sites and rearrange when thematerial is strained. This type of bonding, e.g. pressure bonding canhelp increasing the level of mobility of the fibers. Indeed, the fiberstend to pull out from the bond sites under tension. The acquisitionlayer exhibits a basis weight from 10 to 120 gsm or from 10 to 100 gsmor from 10 to 80 gsm.

The topsheet 24 and/or acquisition layer 52 may have a density from 0.01to 0.4 g/cm³ or from 0.01 to 0.25 g/cm³ or from 0.04 to 0.15 g/cm³.

The topsheet 24 and acquisition layer 52 may be joined together prior orduring the mechanical deformation. If desired an adhesive, chemicalbonding, resin or powder bonding, or thermal bonding between thetopsheet 24 and acquisition layer 52 may be selectively utilized to bondcertain regions or all of the topsheet 24 and acquisition layer 52together. In addition, the topsheet 24 and acquisition layer 52 may bebonded during processing, for example, by carding the topsheet 24 ofonto the acquisition layer 52 and thermal point bonding the combinedlayers.

Prior to any mechanical deformation, the topsheet 24 may be attached tothe acquisition layer 52. For instance, the topsheet 24 may be attachedto the acquisition layer 52 where the topsheet 24 and the acquisitionlayer 52 overlaps. The attachment of the topsheet 24 to the acquisitionlayer 52 may include a uniform continuous layer of adhesive, adiscontinuous patterned application of adhesive or an array of separatelines, spirals, or spots of adhesive. The basis weight of the adhesivein the topsheet/acquisition layer laminate 245 may be from 0.5 to 30 gsmor from 1 to 10 gsm or from 2 to 5 gsm.

Example

The topsheet and the acquisition layer were attached to each other witha hot melt adhesive applied in form of spirals with a basis weight of 5gsm. The acquisition layer was centered onto the topsheet with respectto the topsheet and placed 50 mm from the front MD edge of the topsheet.The topsheet and acquisition layer attached together form a compositeweb.

The topsheet and acquisition layer attached together have beensimultaneously mechanically deformed by passing them between a pair ofintermeshing male and female rolls. The topsheet of thetopsheet/acquisition layer laminate was in contact with the male roll.The acquisition layer of the topsheet/acquisition layer laminate was incontact with the female roll. The teeth on the male roll have a roundeddiamond shape like that shown in FIG. 14A, with vertical sidewalls and aradiused or rounded edge at the transition between the top and thesidewalls of the tooth. The teeth are 0.186 inch (4.72 mm) long and0.125 inch (3.18 mm) wide with a CD spacing of 0.150 inch (3.81 mm) andan MD spacing of 0.346 inch (8.79 mm) The recesses in the mating femaleroll also have a rounded diamond shape, similar to that of the maleroll, with a clearance between the rolls of 0.032-0.063 inch (0.813-1.6mm) The process speed was 800 fpm and the depth of engagement (DOE) was0.155 inch (3.94 mm), with the topsheet being in contact with the maleroll and the acquisition layer being in contact with the female roll.

The topsheet of the topsheet/acquisition layer laminate was ahydrophilic coated mono component high elongation spunbond polypropylene(HES PP) nonwoven material with a density of 0.11 g/cm³. The monocomponent HES PP nonwoven material for the topsheet has an overall basisweight of 20 gsm. The mono component HES PP nonwoven material was firstcoated with a finish made of a fatty acid polyethylene glycol ester forthe production of a permanent hydrophilic mono component HES PP nonwovenmaterial. The topsheet of the topsheet/acquisition layer laminate had awidth of 168 mm and a length of 488 mm.

The acquisition layer of the topsheet/acquisition layer laminate was aspunbond nonwoven with a basis weight of 60 gsm with a density of 0.13g/cm³. The acquisition layer comprises 7 denier PET/coPET (polyethyleneterephthalate) trilobal bicomponent fibers with a 70/30 ratio ofPET/coPET which has been treated with a surfactant. The acquisitionlayer of the topsheet/acquisition layer laminate had a width of 90 mmand a length of 338 mm.

Prototype Diapers for the Example

Diaper prototypes for the above example were produced using PampersActive Fit S4 (size 4) diaper commercially available in Germany inNovember 2014. Pampers Active Fit S4 (size 4) diaper comprises atopsheet, an acquisition layer beneath the topsheet, a distributionlayer beneath the acquisition layer, an absorbent core between thedistribution and a backsheet beneath the absorbent core. Diaperprototypes for the above example were produced using Pampers Active FitS4 (size 4) diaper.

The topsheet and acquisition layer attached together for the aboveexample were placed on top of a Pampers Active Fit diaper commerciallyavailable in Germany in November 2014 from where the commercial topsheetand acquisition layer were removed while keeping the distribution layerin place. For each diaper prototype based on the above example, thetopsheet/acquisition layer laminate were placed on top of thedistribution layer with the three-dimensional protrusions protrudingtowards the backsheet.

The acquisition layer front edge is placed 10 mm from the distributionlayer front edge. The topsheet/acquisition layer laminate was attachedonto the distribution layer and the absorbent core with a hot meltadhesive applied all over the side of the topsheet/acquisition layerlaminate facing the distribution layer. The hot melt adhesive wasapplied in form of spirals with a basis weight of 5 gsm.

The three-dimensional protrusions of the topsheet/acquisition layerlaminate were protruding towards the backsheet because the topsheet ofthe topsheet/acquisition layer laminate was in contact with the maleroll, as set out above.

Each prototype diaper was compacted in a bag at an In Bag Stack Height,i.e. the total caliper of 10 bi-folded diapers, of 90 mm for 1 week.Then the bag was opened and the diapers out of the bag were conditionedat least 24 hours prior to any testing at 23° C.+/−2° C. and 50%+/−10%Relative Humidity (RH).

The measured protrusion height and the measured protrusion base width ofthe three-dimensional protrusions of the topsheet/acquisition layerlaminate have been measured according to the respective ProtrusionsHeight and Protrusion Base Width Test Methods (Table 1).

TABLE 1 Average measurements of the height and width of the protrusionsExample Standard average deviation Measured Protrusion Base Width, mm2.60 0.20 Measured Protrusion Height, mm 1.30 0.20

Test Methods Wet Burst Test Method

The Wet Burst Strength as used herein is a measure of the ability of afibrous structure to absorb energy, when wet and subjected todeformation with regard to the plane of the fibrous structure.

The wet burst strength of a fibrous structure (referred to as “sample”within this test method) is determined using an electronic burst testerand specified test conditions. The results obtained are averaged out of4 experiments and the wet burst strength is reported for a fibrousstructure 55 consisting of one single layer of wet-laid fibers.

Equipment

Apparatus: Burst Tester—Thwing-Albert Vantage Burst Tester or equivalentball burst instrument where the ball moves downward during testing.Refer to manufacturer's operation and set-up instructions. The balldiameter is 1.59 cm and the clamp opening diameter is 8.9 cm.

Calibration Weights—Refer to manufacturer's Calibration instructions

Conditioned Room Temperature and Humidity controlled within thefollowing limits for Laboratory testing:

-   -   Temperature: 23°±1° C.    -   Relative humidity: 50%±2%

Paper Cutter—Cutting board, 600 mm size

Scissors—100 mm, or larger

Pan—Approximate Width/Length/Depth: 240×300×50 mm, or equivalent

Distilled water at the temperature of the conditioned room used

Sample Preparation

The fibrous structure 55 may be unwound from the roll.

The samples to be tested are conditioned in the conditioned room for 24hours immediately before testing. All testing occurs within theconditioned room.

Cut the samples so that they are approximately 228 mm in length andwidth of approximately 140 mm in width.

Operation

Set-up and calibrate the Burst Tester instrument according to themanufacturer's instructions for the instrument being used.

Holding the sample by the narrow edges, the center of the sample isdipped into a pan filled approximately 25 mm from the top with distilledwater. The sample is left in the water for 4 (±0.5) seconds.

The excess water is drained from the sample for 3 (±0.5) seconds holdingthe sample in a vertical position.

The test should proceed immediately after the drain step. The sampleshould have no perforations, tears or imperfections in the area of thesample to be tested. If it does, start the test over.

The sample is placed between the upper and lower rings of the BurstTester instrument. The sample is positioned centered and flat on thelower ring of the sample holding device in a manner such that no slackin the sample is present.

The upper ring of the pneumatic holding device is lowered to secure thesample.

The test is started. The test is over at sample failure (rupture) i.e.,when the load falls 20 g from the peak force. The maximum force value isrecorded.

The plunger will automatically reverse and return to its originalstarting position.

The upper ring is raised in order to remove and discard the testedsample.

The procedure is repeated until all replicates have been tested.

Calculation

Wet Burst Strength=sum of peak load readings/number of replicates tested

Report the Wet Burst results to the nearest gram.

Accelerated Compression Method

-   -   1. Cut 10 samples of the topsheet/acquisition layer laminate 245        (called herein specimen) to be tested and 11 samples of paper        towel into a 3 inch×3 inch (7.6 cm×7.6 cm) square.    -   2. Measure the caliper of each of the 10 specimens at 2.1 kPa        and a dwell time of 2 seconds using a Thwing-Albert ProGage        Thickness Tester or equivalent with a 50-60 millimeter diameter        circular foot. Record the pre-compression caliper to the nearest        0.01 mm.    -   3. Alternate the layers of the specimens to be tested with the        paper towels, starting and ending with the paper towels. The        choice of paper towel does not matter and is present to prevent        “nesting” of the protrusions in the deformed samples. The        samples should be oriented so the edges of each of the specimens        and each of the paper towels are relatively aligned, and the        protrusions in the specimens are all oriented the same        direction.    -   4. Place the stack of samples into a 40° C. oven and place a        weight on top of the stack. The weight must be larger than the        foot of the thickness tester. To simulate high pressures or low        in-bag stack heights, apply 35 kPa (e.g. 17.5 kg weight over a        70×70 mm area). To simulate low pressures or high in-bag stack        heights, apply 7 kPa (e.g. 3.5 kg weight over a 70×70 mm area).    -   5. Leave the samples in the oven for 15 hours. After the time        period has elapsed, remove the weight from the samples and        remove the samples from the oven.    -   6. Within 30 minutes of removing the samples from the oven,        measure the post-compression caliper as directed in step 2        above, making sure to maintain the same order in which the        pre-compression caliper was recorded. Record the        post-compression caliper of each of the 10 specimens to the        nearest 0.01 mm.    -   7. Let the samples rest at 23±2° C. and at 50±2% relative        humidity for 24 hours without any weight on them.    -   8. After 24 hours, measure the post-recovery caliper of each of        the 10 specimens as directed in step 2 above, making sure to        maintain the same order in which the pre-compression and        post-compression calipers were recorded. Record the        post-recovery caliper of each of the 10 specimens to the nearest        0.01 mm. Calculate the amount of caliper recovery by subtracting        the post-compression caliper from the post-recovery caliper and        record to the nearest 0.01 mm.    -   9. If desired, an average of the 10 specimens can be calculated        for the pre-compression, post-compression and post-recovery        calipers.

Protrusion Base Width and Protrusion Height Test Methods

-   -   1) General Information

The Measured Protrusion Base Width and Measured Protrusion Height of thethree-dimensional protrusions of the topsheet/acquisition layer laminateof an absorbent article are measured using a GFM Primos Optical Profilerinstrument commercially available from GFMesstechnik GmbH, WarthestraBe21, D14513 Teltow/Berlin, Germany. Alternative suitable non-touchingsurface topology profilers having similar principles of measurement andanalysis, can also be used, here GFM Primos is exemplified.

The GFM Primos Optical Profiler instrument includes a compact opticalmeasuring sensor based on a digital micro mirror projection, consistingof the following main components:

-   -   a) DMD projector with 800×600 direct digital controlled        micro-mirrors    -   b) CCD camera with high resolution (640×480 pixels)    -   c) Projection optics adapted to a measuring area of at least        30×40 mm    -   d) Recording optics adapted to a measuring area of at least        30×40 mm    -   e) A table tripod based on a small hard stone plate    -   f) A cold light source (an appropriate unit is the KL 1500 LCD,        Schott North America, Inc., Southbridge, Mass.)    -   g) A measuring, control, and evaluation computer running ODSCAD        6.3 software

Turn on the cold-light source. The settings on the cold-light source areset to provide a color temperature of at least 2800K.

Turn on the computer, monitor, and open the image acquisition/analysissoftware. In the Primos Optical Profiler instrument, select “StartMeasurement” icon from the ODSCAD 6.3 task bar and then click the “LiveImage button”.

The instrument is calibrated according to manufacturer's specificationsusing calibration plates for lateral (X-Y) and vertical (Z). SuchCalibration is performed using a rigid solid plate of any non-shinymaterial having a length of 11 cm, a width of 8 cm and a height of 1 cm.This plate has a groove or machined channel having a rectangularcross-section, a length of 11 cm, a width of 6.000 mm and an exact depthof 2.940 mm. This groove is parallel to the plate length direction.After calibration, the instrument must be able to measure the width anddepth dimensions of the groove to within ±0.004 mm.

All testing is performed in a conditioned room maintained at 23±2° C.and 50+/−10% relative humidity. The surface to be measured may belightly sprayed with a very fine white powder spray. Preferably, thespray is NORD-TEST Developer U 89, available from Helling GmbH,Heidgraben, Germany.

2) Protrusion Base Width Test Method

The topsheet/acquisition layer laminate is extracted from the absorbentarticle by attaching the absorbent article to a flat surface in a tautplanar (i.e. stretched planar) configuration with the topsheet of thetopsheet/acquisition layer laminate facing up. Any leg or cuff elasticsare severed in order to allow the absorbent article to lie flat. Usingscissors, two longitudinal cuts are made through all layers above theabsorbent core (i.e. the core wrap) along the edges of thetopsheet/acquisition layer laminate. Two transversal cuts are madethrough the same layers following the front and back waist edges of theabsorbent article.

The topsheet/acquisition layer laminate and any other layers above theabsorbent core are then removed without perturbing thetopsheet/acquisition layer laminate. Freeze spray (e.g. CRC Freeze Spraymanufactured by CRC Industries, Inc. 885 Louis Drive, Warminster, Pa.18974, USA), or equivalent aid may be used to facilitate removal of theuppermost layers from the absorbent article. The topsheet/acquisitionlayer laminate is then separated from any other layers, including anycarrier layer (e.g. a nonwoven carrier layer, a tissue layer), usingfreeze spray if necessary. If a distribution layer, e.g. a pulpcontaining layer is attached to the topsheet/acquisition layer laminate,any residual cellulose fibers are carefully removed with tweezerswithout modifying the acquisition layer.

The topsheet/acquisition layer laminate with three-dimensionalprotrusions (conditioned at a temperature of 23° C.±2° C. and a relativehumidity of 50%±10% for at least 24 hours) namely “the specimen” is laiddown on a hard flat horizontal surface with the body-facing side upward,i.e. the topsheet of the topsheet/acquisition layer laminate beingupward. Ensure that the specimen is lying in planar configuration,without being stretched, with the specimen uncovered.

A nominal external pressure of 1.86 kPa (0.27 psi) is then applied tothe specimen. Such nominal external pressure is applied withoutinterfering with the topology profile measurement. Such an externalpressure is applied using a transparent, non-shining flat Plexiglas®plate 200 mm by 70 mm and appropriate thickness (approximately 5 mm) toachieve a weight of 83 g. The plate is gently placed on top of thespecimen, such that the center point of the Plexiglas® plate is at least40 mm away from any folds, with the entire plate resting on thespecimen. A fold corresponds to a part of the absorbent article (e.g.the topsheet/acquisition layer laminate) where the absorbent article hasbeen folded for packaging purposes.

Two 50 mm×70 mm metal weights each having a mass of 1200 g (approximatethickness of 43 mm) are gently placed on the Plexiglas® plate such thata 70 mm edge of each metal weight is aligned with the 70 mm edges of thePlexiglas® plate. A metal frame having external dimensions of 70 mm×80mm and interior dimensions of 42 mm×61 mm, and a total weight of 142 g(approximate thickness 6 mm), is positioned in the center of thePlexiglas® plate between the two end weights with the longest sides ofthe frame aligned with the longest sides of the plate.

If the specimen is smaller than 70×200 mm, or if a large enough areawithout a fold is not present, or if an area of interest is close to theedges of the specimen and can't be analyzed with the Plexiglas andweights settings described above, then the X-Y dimensions of thePlexiglas® plate and the added metal weights may be adjusted to reach anominal external pressure of 1.86 kPa (0.27 psi) while maintaining aminimum 30×40 mm field of view. At least 10 complete three-dimensionalprotrusions of the specimen should be captured in the field of view of30 mm×40 mm.

Position the projection head to be normal to the specimen surface (i.e.to the topsheet of the topsheet/acquisition layer laminate).

Adjust the distance between the specimen and the projection head forbest focus.

In the Primos Optical Profiler instrument, turn on the button “Pattern”to make a red cross appear on the screen ross and a black cross appearson the specimen.

Adjust the focus control until the black cross is aligned with the redcross on the screen.

Adjust image brightness then capture a digitized image.

In the Primos Optical Profiler instrument, change the aperture on thelens through the hole in the side of the projector head and/or alteringthe camera “gain” setting on the screen.

When the illumination is optimum, the red circle at the bottom of thescreen labeled “I.O.” will turn green.

Click on the “Measure” button.

The topology of the upper surface of the topsheet/acquisition layerlaminate specimen is measured through the Plexiglas plate over theentire field of view 30 mm×40 mm. It is important to keep the specimenstill stationary during this time in order to avoid blurring of thecaptured image. The image should be captured within the 30 secondsfollowing the placement of the Plexiglas plate, metal weights and frameon top of the specimen.

After the image has been captured, the X-Y-Z coordinates of every pixelof the 40 mm×30 mm field of view area are recorded. The X direction isthe direction parallel to the longest edge of the rectangular field ofview, the Y direction is the direction parallel to the shortest edge ofthe rectangular field of view. The Z direction is the directionperpendicular to the X-Y plane. The X-Y plane is horizontal while the Zdirection is vertical, i.e. orthogonal to the X-Y plane.

These data are smoothed and filtered using a polynomial filter (n=6), amedian filter 11 pixels by 11 pixels, and a structure filter 81 pixelsby 81 pixels. The polynomial filter (n=6) approximates the X-Y-Zcoordinate surface with a polynomial of order 6 and returns thedifference to the approximated polynomial. The median filter 11 pixelsby 11 pixels divides the field of view (40 mm×30 mm) in X-Y squares of11 pixels by 11 pixels. The Z coordinate of the pixel located at thecenter of a given 11 pixels by 11 pixels square will be replaced by themean Z value of all the pixels of this given square. The structurefilter 81 pixels by 81 pixels, removes the waviness of the structure andtranslates all the Z peak values belonging to the bottom surface of thePlexiglas plate to a top X-Y plane.

A Reference Plane is then defined as the X-Y plane intercepting thesurface topology profile of the entire field of view (i.e. 30 mm×40 mm),100 microns below this top X-Y plane. In the Primos Optical Profilerinstrument, to measure the Material Area of the Reference Plane (Z=−0.1mm), click on the button “Evaluate”. Then, apply a pre-filtering routineincluding a polynomial filter (n=6), a median filter 11 by 11 and astructure filter (n=81) using the function “Filter”. Save the image to acomputer file with “.omc” extension.

The same above procedure is then executed on the topsheet/acquisitionlayer laminate with the garment-facing side upward (i.e. the acquisitionlayer of the topsheet/acquisition layer laminate being upward), the 40mm×30 mm field of view being located at the exact same X-Y position ofthe topsheet/acquisition layer laminate.

The Empty Area of the reference plane can be defined as the area of theReference Plane that is above the surface profile. The Empty Areashaving boundaries strictly located inside the field of view area (i.e.30 mm×40 mm) without crossing or overlapping with the boundaries of thefield of view area (i.e. 40 mm×30 mm) are defined as Isolated EmptyArea(s). The Measured Protrusion Base Width is defined for an IsolatedEmpty Area as the diameter of the biggest circle that can be inscribedinside a given Isolated Empty Area. This circle should only overlap withthe Isolated Empty Area.

In the Primos Optical Profiler instrument, this can be done by clickingon “Draw circle” and drawing the biggest inscribed circle possible in achosen Isolated Empty Area. Click on “Show sectional picture”, thecircle diameter can be measure via clicking on the extremity of thesectional picture profile and then clicking on “Horizontal distance” toobtain the Protrusion Base Width.

For both of the acquired and digitized images, the Protrusion Base Widthof all the Isolated Empty Areas is determined. Then, the MeasuredProtrusion Base Width is calculated as the arithmetic average of the 6biggest Protrusion Base Widths.

3) Protrusion Height Test Method

The topsheet/acquisition layer laminate is extracted from the absorbentarticle as described above in the Protrusion Base Width Test Method.

The topsheet/acquisition layer laminate specimen comprisingthree-dimensional protrusions is then conditioned and scanned under apressure of 1.86 kPa (0.27 psi) with the body-facing side upward, i.e.the topsheet of the topsheet/acquisition layer laminate being upward asdescribed above in the Protrusion Base Width Test Method.

After the image has been captured, the X-Y-Z coordinates of every pixelof the 40 mm×30 mm field of view area are recorded and smoothed/filteredas described above in the Protrusion Base Width Test Method. A referenceplane is also defined as described above in the Protrusion Base WidthTest Method.

In the Primos Optical Profiler instrument, to measure the Material Areaof the Reference Plane (Z=−0.1 mm), click on the button “Evaluate”. Thenapply a pre-filtering routine including a polynomial filter (n=6), amedian filter 11 by 11 and a structure filter (n=81) using the function“Filter”. Save the image to a computer file with “.omc” extension.

The same above procedure set out in the Protrusion Base Width TestMethod is then executed on the topsheet/acquisition layer laminate withthe garment-facing side upward (i.e. the acquisition layer of thetopsheet/acquisition layer laminate being upward), the 40 mm×30 mm fieldof view being located at the exact same X-Y position of thetopsheet/acquisition layer laminate.

The Empty Area of the reference plane can be defined as the area of theReference Plane that is above the surface profile. The Empty Area havingboundaries strictly located inside the field of view area (i.e. 30 mm×40mm) without crossing or overlapping with the boundaries of the field ofview area (i.e. 40 mm×30 mm) are defined as Isolated Empty Area(s). TheProtrusion Height is defined for an Isolated Empty Area as the distancebetween the minimum Z value of the points of the topsheet/acquisitionlayer laminate surface profile having X-Y coordinates located in thisIsolated Empty Area, and the Z value of the top X-Y plane.

Click on “Draw N parallel lines” and draw a first segment parallel tothe X axis of the field of view (direction of the longest dimension ofthe field of view) passing through the center of the Isolated Empty Areaand extending outside the Isolated Empty Area boundaries. The center ofthe Isolated Empty Area corresponds to the middle of the segmentparallel to the Y axis of the field of view and joining the biggest andsmallest Y value of the Isolated Empty Area. Then input the “number” oflines to be drawn and set the “distance” between lines to 0.05 mm.Enough lines need to be drawn such to cover the entire Isolated EmptyArea. Leave the averaging parameter to 0 then click “Ok”. Then click on“Show sectional picture”. Click on the point of the sectional pictureprofile having the minimum Z value and click on “Vertical distance” toobtain the Protrusion Height.

For both of the acquired and digitized images, the Protrusion Height ofall the Isolated Empty Areas is determined. Then, the MeasuredProtrusion Height is calculated as the arithmetic average of the 6biggest Protrusion Heights.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A process of making an absorbent articlecomprising the steps of: (a) providing a liquid permeable topsheet webextending substantially continuously in a machine direction, thetopsheet web having a first and second surface, a liquid impermeablebacksheet web extending substantially continuously in the machinedirection and an acquisition layer having a first and second surface,the topsheet web and the acquisition layer comprising fibers; (b)aligning the topsheet web and the acquisition layer in a face to facerelationship such that the second surface of the topsheet web is incontact with the first surface of the acquisition layer; (c)simultaneously mechanically deforming and combining the topsheet webtogether with the acquisition layer to provide a topsheet/acquisitionlayer laminate web having three-dimensional protrusions, wherein thethree-dimensional protrusions are formed from the fibers of the topsheetweb and the acquisition layer, wherein a majority of thethree-dimensional protrusions each comprises a base forming an opening,an opposed distal portion, and one or more side walls between the basesand the distal portions of the majority of the three-dimensionalprotrusions, wherein the base, distal portion and the one or more sidewalls are formed by fibers such that the majority of thethree-dimensional protrusion has only an opening at the base; wherein awidth of the acquisition layer is less than a width of the topsheet webin a cross direction; the topsheet/acquisition layer laminate web havinga first surface comprising the second surface of the acquisition layer;and (e) joining a portion of the backsheet web to a portion of thetopsheet web of the topsheet/acquisition layer laminate web such thatthe first surface of the topsheet/acquisition layer laminate web isfacing towards the backsheet web.
 2. The process of claim 1 comprisingthe steps of: (a) providing a dry-laid fibrous structure or a wet-laidfibrous structure; (b) depositing the dry-laid fibrous structure or thewet-laid fibrous structure on the first surface of thetopsheet/acquisition layer laminate web or on the backsheet web; and (c)joining a portion of the backsheet web to a portion of the topsheet webof the topsheet/acquisition layer laminate web wherein the dry-laidfibrous structure or the wet-laid fibrous structure is positionedbetween the topsheet/acquisition layer laminate web and the backsheetweb.
 3. A process of making an absorbent article comprising the stepsof: (a) providing a liquid permeable topsheet web extendingsubstantially continuously in a machine direction, the topsheet webhaving a first and second surface, a liquid impermeable backsheet webextending substantially continuously in the machine direction, anacquisition layer having a first and second surface, a dry-laid fibrousstructure and a carrier layer web having a first and second surface, thetopsheet web and the acquisition layer comprising fibers; (b) aligningthe topsheet web and the acquisition layer in a face to facerelationship such that the second surface of the topsheet web is incontact with the first surface of the acquisition layer; (c)simultaneously mechanically deforming and combining the topsheet webtogether with the acquisition layer to provide a topsheet/acquisitionlayer laminate web having three-dimensional protrusions, wherein thethree-dimensional protrusions are formed from the fibers of the topsheetweb and the acquisition layer, wherein a majority of thethree-dimensional protrusions each comprises a base forming an opening,an opposed distal portion, and one or more side walls between the basesand the distal portions of the majority of the three-dimensionalprotrusions, wherein the base, distal portion and the one or more sidewalls are formed by fibers such that the majority of thethree-dimensional protrusion has only an opening at the base; wherein awidth of the acquisition layer is less than a width of the topsheet webin a cross direction; the topsheet/acquisition layer laminate web havinga first surface comprising the second surface of the acquisition layer;(d) depositing the dry-laid fibrous structure on the first surface ofthe carrier layer web; and (e) joining a portion of the backsheet web toa portion of the topsheet web of the topsheet/acquisition layer laminatewherein the second surface of the carrier layer web is facing thetopsheet/acquisition layer laminate web or the backsheet web.
 4. Theprocess of claim 3 comprising the step of cutting into individualabsorbent articles comprising a backsheet, a topsheet and an acquisitionlayer, characterized in that the topsheet and the acquisition layer arejoined to form a topsheet/acquisition layer laminate.
 5. The process ofclaim 3 comprising the step of providing the acquisition layer isprovided continuously or intermittently in the machine direction.
 6. Theprocess of claim 3 comprising the step of joining the portion of thebacksheet web to the portion of the topsheet web at or adjacent to thetransversal edges of the first surface of the topsheet/acquisition layerlaminate web in the cross direction, wherein the transversal edges ofthe first surface of the topsheet/acquisition layer laminate web is freeof any portion of the acquisition layer.
 7. The process of claim 3comprising providing the dry-laid fibrous structure which comprises amixture of superabsorbent polymers and dry-laid fibers.
 8. The processof claim 3 comprising the step of providing an absorbent core, whereinthe absorbent core comprises an absorbent material.
 9. The process ofclaim 8 wherein the carrier layer web is disposed between thetopsheet/acquisition layer laminate web and the dry-laid fibrousstructure or between the dry-laid fibrous structure and the absorbentcore.
 10. The process of claim 9 wherein the absorbent materialcomprises at least 80% of superabsorbent polymers, up to substantially100% of superabsorbent polymers, by total weight of the absorbentmaterial.
 11. The process of claim 3, wherein step (c) comprises thefollowing steps: (1) providing a first and second forming member havinga machine direction orientation and a cross direction orientation, saidforming members comprising: a first forming member having a surfacecomprising a plurality of discrete, spaced apart male forming elementshaving a base that is joined to the first forming member, a top that isspaced away from the base, and sides that extend between the base andthe top of the male forming elements, a second forming member having asurface defining a plurality of recesses in therein, wherein therecesses are aligned and configured to receive the respective maleforming elements therein; and (2) engaging the topsheet web and theacquisition layer together between the forming members andsimultaneously mechanically deforming and combining the topsheet webtogether with the acquisition layer using the forming members to form atopsheet/acquisition layer laminate web, such that thetopsheet/acquisition layer laminate web comprises deformations formingthe three-dimensional protrusions.
 12. The process of claim 3 whereinthe majority of the three-dimensional protrusions have a shape selectedfrom the group consisting of a bulbous shape, a conical shape, amushroom shape and combinations thereof when the three-dimensionalprotrusions are viewed from a cross-sectional view in a Z-direction. 13.The process of claim 3 comprising the step of forming thetopsheet/acquisition layer laminate web by nesting together the topsheetweb and the acquisition layer, wherein the three-dimensional protrusionsof the topsheet web coincide with and fit together with thethree-dimensional protrusions of the acquisition layer.
 14. The processof claim 3 comprising the step of forming the topsheet/acquisition layerlaminate web by interrupting one of the topsheet web or the acquisitionlayer such that the three-dimensional protrusions of the respectiveother non-interrupted topsheet web or acquisition layer interpenetratethe interrupted topsheet web or acquisition layer
 15. The process ofclaim 3 comprising the step of forming the topsheet/acquisition layerlaminate web by interrupting one of the topsheet web or the acquisitionlayer in the area of the three-dimensional protrusions of thetopsheet/acquisition layer laminate web such that the three-dimensionalprotrusions of the respective other non-interrupted topsheet web oracquisition layer at least partially fit together with thethree-dimensional protrusions of the interrupted topsheet web oracquisition layer.
 16. The process of claim 3 comprising the step offorming the topsheet/acquisition layer laminate web by interrupting thetopsheet web and the acquisition layer in the area of thethree-dimensional protrusions of the topsheet/acquisition layer laminateweb and the three-dimensional protrusions of the topsheet web coincidewith and fit together with the three-dimensional protrusions of theacquisition layer, and wherein the interruptions in the topsheet web inthe area of the three-dimensional protrusions of thetopsheet/acquisition layer laminate web does not coincide with theinterruptions in the acquisition layer in the area of thethree-dimensional protrusions of the topsheet/acquisition layer laminateweb.
 17. The process of claim 3 comprising the step of providing thecarrier layer web which is colored.
 18. The process of claim 3comprising the step of providing the topsheet web, the acquisitionlayer, and/or the carrier layer web with an indicia thereon.
 19. Theprocess of claim 3 comprising the step of applying an indicia to thetopsheet web, the acquisition layer, and/or the carrier layer web. 20.The process of claim 3 comprising the step of printing an indicia on thetopsheet web, the acquisition layer, and/or the carrier layer web.